01

Installation and Operation Manual

Revision 8
for the REXA Xpac Series 3 9/2022 - Present
ISO 9001
REXA Electraulic™ Actuators and Drives

Serial #...........................................................
Model #..........................................................
Application...................................................
Tag #...............................................................
REXA Xpac Series 3 - Installation and Operation Manual - 9/22
Xpac Series 3 - Installation and Operation Manual - 9/22 i

Table of Contents

Table of Contents Figure 1.6.3 Accumulator Pressure Gauge...................................... 7

1.6.4 Filling................................................................................................7
Table of Contents.................................................................................................. i PROCEDURE (9 steps):.............................................................................7
Fundamental Safety Information.................................... v Figure 1.6.4-1 Castrol EDGE................................................................ 7
WARNINGS...................................................................................................v Figure 1.6.4-2 Fill Valve with cover.................................................. 7
WARNING LABELS.....................................................................................v Figure 1.6.4-3 Fill the oil gun.............................................................. 7
RESIDUAL RISKS.........................................................................................vi Figure 1.6.4-4 Purge the air................................................................ 8
Education and Discipline........................................................................viii Figure 1.6.4-5 Oil Pump Valve............................................................ 8
Figure 1.6.4-6 Fill Valve with Schrader fitting................................ 8
Product Compliance......................................................... ix
1.6.5 Overfilling, Oil Weeping, and Thermal Expansion............9
Information.................................................................................................ix
1.6.6 Air Purging .....................................................................................9
SPECIFIC CONDITIONS OF USE (Zone 1) IECEx CSA 16.0041X...x
1.6.7 Thermal Expansion Chamber Purging..................................9
SPECIFIC CONDITIONS OF USE (Zone 1)SIRA 17ATEX1231X.....xii
Figure 1.6.7-1 Purge Ports.................................................................. 9
SPECIFIC CONDITIONS OF USE (Zone 2) IECEx CSA 17.0013X...xiii
SPECIFIC CONDITIONS OF USE (Zone 2) SIRA 17ATEX4360X....xv Figure 1.6.7-2 Full Indicator “OK”– flush with front face............. 10
EC DECLARATION OF CONFORMITY...................................................xvi 1.6.8 Hydraulic System Purging.........................................................10
EU Declaration of Conformity...............................................................xvii Figure 1.6.8-1 Extend/CW and Retract/CCW Ports....................... 10
EU Declaration of Conformity...............................................................xviii Figure 1.6.8-2 Bleed Kit (PN: K09275)............................................... 11
Declaration of Noise Emission..............................................................xix 1.7 Tool Requirements (Power Module Only).................................11
Waiver Of Translations Agreement....................................................xx 1.8 Theory Of Operation.........................................................................11
Waiver of Main Supply Disconnect/Emergency Stop Agreement...xxi 1.8.1 Overview.........................................................................................11
1.8.2 Actuator..........................................................................................12
1 General Information...................................................... 1 Figure 1.8.2-1 B Module...................................................................... 12
1.1 About REXA.........................................................................................1
Figure 1.8.2-2 C Module...................................................................... 12
1.2 Factory Support.................................................................................1
Figure 1.8.2-3 1/2D Module.................................................................. 13
1.3 Actuator Identification....................................................................1
Figure 1.8.2-4 D Module...................................................................... 13
Figure 1.3 ID Tag................................................................................... 2
Figure 1.8.2-5 C Module...................................................................... 13
1.3.1 Model Number.............................................................................2
Figure 1.8.2-6 D Module...................................................................... 13
Figure 1.3.1 Model Number............................................................... 2
1.8.3 Control Sub-Assembly................................................................14
1.3.2 Serial Number................................................................................3
Figure 1.8.3 Typical Control Enclosure............................................ 14
1.3.3 Build Number................................................................................3
316 Stainless-Steel Enclosure Specifications For
1.4 General Specifications......................................................................3
1.4.1 Recommended Fluids and Lubricants..................................3 Single Module Actuators:....................................................................14
1.4.2 Operating Temperatures..........................................................3 1.8.4 REXA Terminal Blocks..................................................................15
Table 1.4.2-1 Linear Actuators........................................................... 3 Low Power Terminal Block ..................................................................15
Table 1.4.2-2 Rotary Actuators & Drives.......................................... 4 Figure 1.8.4-1 Low Power Terminal Block........................................ 15
Table 1.4.2-3 CSA Temperature Ratings........................................... 4 Medium Power Terminal Block..........................................................16
1.4.3 Relative Humidity.........................................................................5 Figure 1.8.4-2 Medium Power Terminal Block................................ 16
1.4.4 Transportation and Storage.....................................................5 High Power Terminal Block.................................................................17
1.5 Maintenance Schedule....................................................................5 Figure 1.8.4-3 High Power Terminal Block....................................... 17
Quarterly....................................................................................................5 High Power Terminal Block.................................................................18
1.6 Oil.............................................................................................................5 Figure 1.8.4-4 Female Plug Pinout Connection............................. 18
1.6.1 Oil Level Inspection ....................................................................5 Figure Recommended Installation Practices................................19
1.6.2 Standard Units...............................................................................6 Table 1.8.4-1 Control Enclosure Terminal Blocks........................... 19
Figure 1.6.2-1 Add oil indication........................................................ 6 Table 1.8.4-2 Actuator Terminal Blocks............................................ 19
Figure 1.6.2-2 Full oil indication........................................................ 6 Figure 1.8.4-5 Wire Termination Hub............................................... 19
Figure 1.6.2-3 Oil Expansion............................................................... 6 1.8.5 Operational Summary................................................................20
Figure 1.6.2-4 External Auxiliary Expansion Chamber................. 6 Figure 1.8.5-1 Hydraulic Schematic................................................. 20
1.6.3 Accumulator Fail...........................................................................7 Figure 1.8.5-2 Bypass........................................................................... 20

Table of Contents
 ii Table of Contents

2 Delivery.......................................................................... 21 6 Modes of Operation & Control Parameters................. 40

2.1 Receipt...................................................................................................21 Figure 6.0.1 Display Label on Inside of Flip Cover......................... 40
2.2 Storage...................................................................................................21 Figure 6.0.2 Modes of Operation....................................................... 40
2.3 Unpacking............................................................................................21
2.3.1 Unpacking System, Lifting........................................................21 Figure 6.0.3 Control Parameters Menu............................................ 41
2.4 Installation Requirements...............................................................21 6.1 Setup Mode..........................................................................................42
2.4.1 Operational and Maintenance Clearances..........................21 6.1.1 Menu Navigation..........................................................................42
2.4.2 Hazards Due to Height...............................................................21 6.1.2 Changing a Parameter................................................................42
3 Electrical Installation..................................................... 22 6.1.3 CALIBRATE Menu..........................................................................42
Control Enclosure Overview.................................................................22 6.1.4 Control Menu.................................................................................43
3.1 Control Enclosure Installation.....................................................22
Figure 3.1 Electrical Installation Block Diagram........................... 22 Figure 6.1.4 Gain................................................................................... 43
3.2 Main Power........................................................................................23 6.1.5 Speed Menu...................................................................................44
Table 3.2 Power Requirements........................................................... 23 6.1.6 INPUTS Menu.................................................................................44
Figure 3.2 Control Enclosure............................................................... 23 6.1.7 Drives Menu...................................................................................45
3.2.1 Supply Disconnect Device........................................................24
3.2.2 Grounding......................................................................................24 6.1.8 Outputs Menu...............................................................................47
3.2.3 Grounding Symbols....................................................................24 6.1.9 Current Stats Menu and Historic Stats Menu.....................48
3.2.4 Main Power Supply Wiring........................................................25 Messages in CPU Display Error Status:............................................49
3.2.5 Cordage...........................................................................................25 Power Supply Errors...............................................................................49
3.2.6 Fuse Identification / Replacement..........................................26
System Configuration Errors...............................................................49
Table 3.2.6-1 CSA/General Locations
Fuse Replacement/Identification...................................................... 26 Motor Errors..............................................................................................49
Table 3.2.6-2 ATEX/IEC Locations Dual Servo Faults:...................................................................................49
Fuse Replacement/Identification...................................................... 26 Accumulator Servo Faults:...................................................................49
Table 3.2.6-3 Power Supply Identification...................................... 27 Servo Primary Booster Faults:.............................................................49
3.3 Conduit and Conduit Fittings........................................................27
Dual Servo Booster Faults:...................................................................49
4 Mechanical Installation................................................. 28 Primary Induction Drive Faults:.........................................................49
4.1 Pre-Installation Checklist.................................................................28
4.2 R Series (Rotary)..................................................................................28 Induction Booster Drive Faults:.........................................................49
4.2.1 Rotary Mounting (Fail in Place)...............................................28 Primary Stepper Drive Faults:.............................................................49
4.2.2 Rotary Mounting (Universal Spring Fail)..............................29 Dual Stepper Drive Faults:...................................................................49
Figure 4.2.2 Solenoid Override Position.......................................... 29 Accumulator Stepper Drive Faults:...................................................49
4.2.3 Rotary Mounting Accumulator...............................................30
4.3 L Series (Linear) ..................................................................................30 6.2 Auto Mode ...........................................................................................49
4.3.1 Linear Mounting (Fail in Place)................................................30 6.2.1 Display Fields in Auto Mode.....................................................49
4.3.2 Linear Mounting (Spring Fail)..................................................31 Figure 6.2.1 Display Fields................................................................... 49
Figure 4.3.2 Solenoid Override Position.......................................... 31 6.2.2 Display Information....................................................................50
4.3.3 Linear Mounting Accumulator................................................31
4.4 D Series (Drive)....................................................................................32 6.2.3 Parameter Viewing.......................................................................50
4.4.1 Drive Mounting.............................................................................32 A. Mechanical Limit Switches.......................................... A-1
Table 4.4.1- Drive Base Bolting........................................................... 32
A.1 Linear.....................................................................................................A-1
4.4.2 Drive Arm........................................................................................33
Figure 4.4.2-1 Drive Arm Assembly Reference Drawing.............. 33 Figure A.1 Linear Limit Switches....................................................... A-1
Figure 4.4.2-2 Drive Arm Alignment................................................ 33 A.1.1 General Specifications...............................................................A-1
5 Start-Up Considerations............................................... 34 A.1.2 Linear Wiring.................................................................................A-1
5.1 Start-Up Checklist..............................................................................34 A.1.3 Linear Adjustment......................................................................A-1
5.1.1 Inspection of Electronic Sub-Assembly Installation........34 A.2 Rotary.....................................................................................................A-2
5.1.2 Inspection of Mechanical Actuator Installation................34 Figure A.2 Rotary Limit Switch Schematic..................................... A-2
5.2 Alignment.............................................................................................35
5.2.1 Lateral Alignment........................................................................35 A.2.1 General Specifications...............................................................A-2
5.2.2 Longitudinal Alignment............................................................35 A.2.2 Rotary Wiring.................................................................................A-2
5.3 Initial Calibration................................................................................35 A.2.3 Rotary Adjustment......................................................................A-2
5.4 Rotary and Drive Spring Stops......................................................37 Figure A.2.3 Rotary Limit Switch....................................................... A-2
Figure 5.4 Universal Spring Alignment........................................... 37
5.5 Cylinder End Stops.............................................................................37 A.3 Rotary Valve Position Monitor (VPM)..........................................A-3
Figure 5.5 Stroke Adjustment............................................................ 37 A.3.1 General Specifications...............................................................A-3
5.5.1 End Stop Adjustment....................................................................38 Figure A.3.1.1: REXA VPM..................................................................... A-3
Figure 5.5.1-1 Cylinder End Stops..................................................... 38 Figure A.3.1.2: Sensor, Terminal & Switches.................................... A-3
Figure 5.5.1-2 End Stop Detail........................................................... 39
Table 5.5.1 Stroke Adjustor................................................................. 39 Figure A.3.1.3: Limit-Switches 11HM1............................................. A-3
5.5.2 R200 000/R400 000 End Stroke Adjustments........................39 A.3.2 Adjustment....................................................................................A-3
Figure 5.5.2 R200 000/R400 000 Stroke Adjuster........................... 39 Figure A.3.2: Rotary Touchless sensor.............................................. A-3

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Xpac Series 3 - Installation and Operation Manual - 9/22 iii

B. Stem Connection & Seat Loading Methods................ B-1 E.1 Bluetooth Graphical User Interface.......................... E-1
B.1 Theory of Operation..........................................................................B-1 E.1 Bluetooth Connection......................................................................E-1
B.2 Elastic Coupling..................................................................................B-1 Figure 1.1 Desktop Icon....................................................................... E-1
Figure 1.2 Initial Screen........................................................................ E-1
Figure B.2-1 Preloaded Coupling...................................................... B-1
Figure 1.3 Bluetooth Connection....................................................... E-2
Figure B.2-2 Rated Load Coupling.................................................... B-1 Figure 1.4 Search for Actuators.......................................................... E-2
B.3 Seat Loading Cylinder......................................................................B-2 Figure 1.5 Enter Pairing Key................................................................ E-3
Figure B.3 Seat Loading Cylinder..................................................... B-2 E.2 Status......................................................................................................E-3
B.3.1 Mechanical Installation..............................................................B-2 Figure 2 Status....................................................................................... E-3
B.3.2 Electrical Installation...................................................................B-2 E.3 PST...........................................................................................................E-4
Table B.3.2 SLC Connections Figure 3 PST............................................................................................ E-4
E.4 Diagnostics...........................................................................................E-4
SLC—½ inch NPT on cylinder (Screw Termination)...................... B-3 Figure 4 Diagnostics............................................................................. E-4
B.4 Solenoid Auto-Seating.....................................................................B-3 E.5 Calibration............................................................................................E-5
B.5 Calibration............................................................................................B-3 Figure 5 Calibration.............................................................................. E-5
Figure B.5-1 SLC Indicator–Seated.................................................... B-3 E.6 Configuration......................................................................................E-5
Figure B.5-2 Reset Switch.................................................................... B-3 Figure 6 Configuration......................................................................... E-5
B.5.1 Reverse Acting Calibration.......................................................B-3 F. Errors and Error Displays.............................................. F-1
Messages in CPU Display Error Status:..............................................F-1
C1. Standard Accumulator Fail-Safe............................... C-1 Power Supply Errors:................................................................................F-3
C1.1 Theory of Operation.......................................................................C-1 System Configuration Errors:................................................................F-3
Figure C1.1 Standard Accumulator Fail-Safe................................. C-1 Motor Errors:...............................................................................................F-4
C1.1.1 Trip Function...............................................................................C-1 Dual Servo Faults:......................................................................................F-5
Figure C1.1.1 (Standard Accumulator) Trip Condition................. C-1 Accumulator Servo Faults:.....................................................................F-6
C1.1.2 Recharge Function....................................................................C-1 Servo Primary Booster Faults: ..............................................................F-7
Dual Servo Booster Faults: ....................................................................F-8
Figure C1.1.2 Recharge Condition.................................................... C-2
Primary Induction Drive Faults: ...........................................................F-8
C1.2 Accumulator Control Parameters..............................................C-2 Induction Booster Drive Faults: ...........................................................F-8
C1.3 Recharging.........................................................................................C-2 Primary Stepper Drive Faults: ..............................................................F-9
C1.4 Manual Override..............................................................................C-3 Dual Stepper Drive Faults: .....................................................................F-9
Figure C1.4-1 Solenoid Manual Accumulator Stepper Drive Faults: ....................................................F-9
Override Levers (Position A)................................................................ C-3 G. Surge Control Option................................................... G-1
Figure C1.4-2 Solenoid Manual G.1 Theory of Operation.........................................................................G-1
Override Levers (Position B)................................................................ C-3 Figure G.1-1 Overshoot....................................................................... G-1
C1.5 Discharging.......................................................................................C-3 Figure G.1-2 Target position.............................................................. G-1
Figure G.1-3 Undershoot.................................................................... G-1
Figure C1.5-1 Bypass Drawing..................................................................C-3
G.2 Installation...........................................................................................G-1
C2. Online Recharge Accumulator Fail-Safe................... C-4 G.3 Calibration............................................................................................G-1
C2.1 Theory of Operation.......................................................................C-4 H. Build Numbers.............................................................. H-1
Figure C2.1 Online Accumulator Fail................................................ C-4 Linear Series Actuator.............................................................................H-2
C2.1.1 Trip Function...............................................................................C-4 Rotary/Drive Series Actuator................................................................H-3
Figure C2.1.1 Trip Condition............................................................... C-5 Electronic Control Enclosure.................................................................H-4
C2.1.2 Recharge Function....................................................................C-5 Mounting Systems....................................................................................H-5
Linear Series Mounting........................................................................H-5
Figure C2.1.2-A Recharge After Trip Condition.............................. C-5 Rotary Series Mounting.......................................................................H-5
Figure C2.1.2-B Online Recharge to Top Off Accumulator Pressure... C-6 Drive Series Mounting.........................................................................H-6
Figure C2.1.2-C Modulation to Follow the Control Signal........... C-6 Linear Fisher Mounting.......................................................................H-6
C2.2 Accumulator Control Parameters..............................................C-6 M. Manual Operators........................................................ M-1
C2.3 Recharging.........................................................................................C-7 M.1 Declutchable Handwheel .............................................................M-1
C2.4 Manual Override..............................................................................C-7 Handwheel Revolutions...................................................................... M-1
Figure C2.4 Manual Override Condition.......................................... C-7 Figure M.1-1 Handwheel Assembly.................................................. M-1
C2.5 Discharging.......................................................................................C-8 Figure M.1-2 Drill Drive........................................................................ M-1
Figure C2.5 Manual Override Condition.......................................... C-8 Figure M.1-3 Drill Drive with Drill...................................................... M-1
M.1.2 Declutchable Drill Drive ............................................................M-1
D. Booster Pump Configuration...................................... D-1 M.2 Manual Hydraulic Pump.................................................................M-2
D.1 Theory of Operation.........................................................................D-1 Figure M.2 Manual Hydraulic Pump................................................ M-2
D.2 Mechanical Installation...................................................................D-1 Manual Hydraulic Pump Speeds (# Of Pumps).............................. M-2
M.3 Fail-Safe Unit Operation.................................................................M-2
D.2.1 Control Enclosure.......................................................................D-1
Figure M.3 Generation 1 Solenoid Manual Override Levers
D.3 Electrical Installation........................................................................D-1 (Position B).............................................................................................. M-2
Important!....................................................................................................D-1 M.3.1 Generation 2 High Speed Solenoid........................................M-3
D.4 Control Parameters...........................................................................D-1 Figure M.3.1 Generation 2 Solenoid................................................ M-3

Table of Contents
 iv Table of Contents

N. HART® Field Device Setup and Specification............. N-1 Q. Contact Input Options................................................. Q-1
Table of Contents......................................................................................N-1 Contact Inputs............................................................................................Q-1
1. DEVICE IDENTIFICATION AND CAPABILITY..................................N-2 Q.1 Signal Input Range............................................................................Q-1
1.1 Capability Checklist........................................................................N-2 ON state:....................................................................................................Q-1
2. TERMS & DEFINITIONS........................................................................N-2 OFF state:...................................................................................................Q-1
3. PRODUCT SCOPE..................................................................................N-3 Q.2 1 Cont....................................................................................................Q-1
4. PRODUCT INTERFACES.......................................................................N-3 Q.3 2 Cont....................................................................................................Q-1
4.1. Host interface...................................................................................N-3 R. Remote Manual Control............................................... R-1
4.2. Install/Update REXA DD...............................................................N-3 R.1 Remote Manual (RemoteMan)......................................................R-1
4.3. Setup Device Polling Address Search Range........................N-5
4.4. Connect to the Actuator..............................................................N-5 S. Safety Manual for ESD SIL Compliance....................... S-1
4.5. Device Online Menu......................................................................N-7 S.1 General...................................................................................................S-1
4.6. Device Settings................................................................................N-7 Figure S-1: Example Safety Instrumented Function...................... S-1
4.7. Monitor X3 Device’s Operation Process..................................N-9 S.2 System Set Up.....................................................................................S-1
4.8. Get X3 Device Diagnostic Information...................................N-9 S.3 System Operation..............................................................................S-1
5. POSSIBLE TROUBLE SHOOTING METHODS.................................N-11 S.4 Safety Critical Components............................................................S-2
5.1. HART Secondary Master Device................................................N-11 S.5 System Diagnostics...........................................................................S-2
6. DYNAMIC VARIABLES...........................................................................N-11 S.6 Site Acceptance Test Procedures..................................................S-2
6.1. Control Signal...................................................................................N-11 S.7 Environmental Requirements........................................................S-2
6.2. Position...............................................................................................N-11 T. Position Transmitter..................................................... T-1
6.3. Torque/ Thrust..................................................................................N-11 T.1 Position Transmitter...........................................................................T-1
6.4. Accumulator.....................................................................................N-11
7. STATUS INFORMATION........................................................................N-11 U. Electronic Relays Limit Switch, Alarm, and Warning... U-1
7.1. Device Status....................................................................................N-11 Electronic Relays........................................................................................U-1
7.2. Extended Device Status...............................................................N-11 U.1 Limit Switch Relays...........................................................................U-1
7.3. Additional Device Status (Command #48)............................N-11 U.2 Alarm and Warning Relay...............................................................U-1
8. UNIVERSAL COMMANDS...................................................................N-13 General Specifications......................................................................... U-1
9. COMMON PRACTICE COMMANDS.................................................N-14 X. Cable Installation Guide for Power and Control Cables... X-1
10. DEVICE-SPECIFIC COMMANDS......................................................N-14 X.1 Connector Installation.....................................................................X-1
11. TABLES ...................................................................................................N-14 X.2 Cable Support.....................................................................................X-1
11.1. Unit Codes .....................................................................................N-14 X.3 Proper Bend Radius...........................................................................X-1
12. UNSUPPORTED MODES...................................................................N-14 X.4 Tying Cables with Cable Ties..........................................................X-1
12.1. Burst Mode.....................................................................................N-14 X.5 Eliminating Stress Points in Cable Dress....................................X-1
12.2. Catch Device Variable.................................................................N-14
Y. Basis Weight Control..................................................... Y-1
O. Output Load Protection............................................... O-1 Y.1. Control Overview..............................................................................Y-1
O.1 Theory of Operation.........................................................................O-1 Y.2. Typical Pulse Response....................................................................Y-1
O.2 Identification.......................................................................................O-1 Y.3. REXA Menu Parameters...................................................................Y-1
Table O.2 Adjustment Range.............................................................. O-1
Figure O.2 Pressure Relief Valve........................................................ O-1 Z. Air Ship Procedures......................................................Z-1
O.3 Adjustment:.........................................................................................O-1 Z.1 Accumulator Systems......................................................................Z-1
O.4 Spring Change:...................................................................................O-1 Z.2 Oil Fill Procedure ..............................................................................Z-4

P. Interconnect Diagrams & Control Enclosure Drawings....P-1

B and C Stepper Enclosure Diagram..................................................P-2
B and C Stepper 115 VAC Wiring Diagram.......................................P-3
B and C Stepper 230 VAC Wiring Diagram.......................................P-4
2C Stepper Enclosure Diagram............................................................P-5
2C Stepper 115VAC Wiring Diagram..................................................P-6
½D and D Servo Enclosure Diagram..................................................P-7
½ D Servo 115VAC Wiring Diagram....................................................P-8
D Servo 230 VAC Wiring Diagram........................................................P-9
Dual ½D and D Servo Enclosure Diagram........................................P-10
2D Servo 230 VAC Wiring Diagram.....................................................P-11
D,P9 Servo 230 VAC Enclosure Diagram...........................................P-12
D,P9 Servo 230 VAC Wiring Diagram..................................................P-13
D,P20 Servo 230 VAC Enclosure Diagram.........................................P-14
D,P20 Servo 230 VAC Wiring Diagram...............................................P-15
D,P40 Servo 230 VAC Enclosure Diagram.........................................P- 16
D,P40 Servo 230 VAC Wiring Diagram...............................................P- 17

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Xpac Series 3 - Installation and Operation Manual - 9/22 v

Fundamental Safety Information

REXA Actuators produce extremely high forces, have hydraulic lines under pressure and have dangerous electrical power input
levels. In addition to these standard characteristics, optional actuator constructions possess other hazards such as coil and disk
springs under compression and high pressure accumulator bottles.

WARNINGS
Based on these hazards, the following could occur if this safety information is not observed:

• Serious physical injury

• Death

• Damage to actuator or other equipment

Always observe the safety information listed in this documentation.

WARNING LABELS
Hazardous Voltage
Turn Off and Lock Out system power before servicing. Do Not Operate this equipment from any power source that
does not match the voltage rating stamped on the equipment. Refer to the manufacturer’s identification nameplate for
operational requirements.

General Warning
Refer to Installation Manual before servicing.

Attention
Important information provided. Do No Use this equipment for any purpose not described in this manual.

Crush or Pinch Point Hazard

Turn Off and Lock Out system power before servicing. Warn of actuator movement if Spring Fail Unit.

Guard Warning
All Guards MUST be in place before operation. Failure to do so may result in injury or damage to equipment.

Tripping, Slipping and Falling Hazards

These hazards can be avoided by cleaning spilled hydraulic oil in a timely manner.

• Airborne noise greater than 80 dB, ear protection suggested.

• Using the actuator for uses other than what it is intended may result in injury or death. Use the actuator for its intended
purpose ONLY.

• Do not use the actuator should it be damaged in shipping or installation. Contact REXA

Fundamental Safety Information

 vi Fundamental Safety Information

RESIDUAL RISKS
This section is to help identify the risks associated with the Actuator System. These items are identified as:

Actuator & Driven Device Connection:

The point at which the actuator couples to the driven device poses the risk of injury due to pinch or crush point. Use
appropriate Lock-Out/Tag-Out procedures when connecting Actuator to the driven device.

Manual Override Handwheel Assembly:

The Manual Override Handwheel Assembly is to remain declutched until it is required. The Motor Shaft Cover MUST be in
place during normal operation. Failure to do so poses a risk of injury.

Manual Override Handwheel Assembly:

When the Manual Override, Handwheel Assembly is used, adhere to proper Lock-Out/Tag-Out procedures.

Feedback Cover:
Feedback Cover MUST be in place during operation. Failure to do so may result in injury. Use proper Lock-Out/Tag-Out
procedures before accessing feedback housing.

Shock Hazard:
Wire Cover must be in place during operation. Use proper 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 qualified service and installation personnel should install or
adjust this device.

Alignment:
Ensure that the actuator shaft is in line with the valve plug stem. Misalignment could damage the actuator and driven
device or cause injury to installation personnel.

Avoid Accidental Starting:

When installing the actuator, insure that line power to the unit is shut off. When power is applied, the actuator may
immediately respond to the control signal. Inadvertent motion could damage the actuator and driven device or cause
injury to installation personnel.

Important:
When machining the control enclosure, thoroughly clean any metal chips or residue from the enclosure before applying
power.

Hydraulic Oil:
The standard oil used in REXA Actuators or drives is Castrol EDGE® SAE 5W-50 motor oil. The introduction of other fluids
may cause damage to the unit.

Spring Under Tension:

REXA Actuators, denoted by an E, R or U as the last character in the model number, contain a spring under tension. Failure
to properly remove this force before disassembly can cause serious injury to maintenance personnel. Contact REXA for
disassembly instructions.

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 vii

Relieving Internal Pressure:

When the electric power is off or the motor is not turning, hydraulic pressure remains locked within the cylinder and/or
accumulator. This internal pressure must be relieved before disconnecting any hydraulic fitting. Open the bypass cylinder
(3/16” hex) located on the power module for fail in place units and manually override all solenoid valves that are closed.

Note: External thermal expansion chamber or accumulator collection bottle lines may contain up to 60 psi (4 bar) that cannot be relieved.

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
Lock-out/Tag-out before servicing.

Most equipment is installed along with safe switches allowing the equipment to be disabled for minor repair. In general, these
switches provide adequate protection for minor repair, which is routine, repetitive, and necessary to the normal use of the equipment.
Lock-Out/Tag-Out procedures should be used for the following situations.

• Major repairs or overhaul.

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

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

• Any situation that threatens an employees safety.

Note: Always follow local & plant procedures.

Procedures: Lock-Out/Tag-Out
The following are minimum recommended procedures to be followed for Lock-Out/Tag-Out:

Notify all affected areas and employees of the impending Lock-Out situation, the reason for it, and estimated start and duration times.

1. 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.

2. 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.

3. 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.

4. Lock-Out verification: 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.

5. 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.

Fundamental Safety Information

 viii Fundamental Safety Information

6. Lock and/or tag removal. All locks and tags are to be left in place until all work is completely finished. This is especially true
when more than one employee is working on the equipment. A lock is never to be removed except by the person who
placed it there.

7. Equipment start-up. Make a final safety check before restarting equipment, to be certain it is safe to operate. Make sure
of the following:

a. All tools and other items have been removed.

b. All machine guards are returned to their proper position. All electric, hydraulic, pneumatic or other systems are
properly reconnected.

c. All employees are clear of equipment.

Many of the Lock-Out/Tag-Out procedures appear to be common sense, and they are. Following them will ensure safe operation
calibration, maintenance and repair of equipment and/or processes, without dangerous surprises or injury.

Education and Discipline

The key to worker safety is education. The purpose of this document is for everyone to understand the importance of Lock-Out/
Tag-Out and how to recognize when it is in use. By educating all employees 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.

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 ix

Product Compliance

Information
Inclusion of the following symbols indicates that the supplied REXA actuator complies with applicable standards:

For the U.S. and Canada: A CSA mark with the indicators “C” and “US” means that the product is certified for both the U.S.
and Canadian markets, to the applicable U.S. and Canadian standards.

CLASS I DIVISION 2 GROUPS A, B, C and D

CLASS I DIVISION 1 GROUPS C and D

IECEx scheme is a single globally accepted certification framework based on ISO and IEC International Standards relating
to Equipment, Services and Persons in areas relating to Explosive Atmospheres.

CLASS I ZONE 1: Ex db [ia IIC] IIB T3

CLASS I ZONE 2: Ex nA [ia] IIC T3 Gc*

(coming soon)

*Note: For Zone 2, the [ia] portion is optional since the actuator portion of the assembly could be located in Zone 1.

The ATEX Directive 2014/34/EU covers equipment and protective systems intended for use in potentially explosive
atmospheres. The Directive defines the essential health and safety requirements and conformity assessment procedures,
to be applied before products are placed on the EU market.

CLASS I ZONE 1: II 2G Ex db [ia IIC] IIB T3

(coming soon)

CLASS I ZONE 2: II 3G Ex nA IIC T3 Gc

This mark indicates that the product is certified for European markets and complies with the applicable Directives for
hazardous protection concepts as well as the Essential Health & Safety Requirements.

Note: for IECEx and ATEX, the ‘X’ marking following the certificate number is used as a means of identifying that essential information
for the installation, use and maintenance of the equipment must be followed as detailed in the following sections.

Product Compliance
 x Product Compliance

SPECIFIC CONDITIONS OF USE (Zone 1) IECEx CSA 16.0041X

General
1. Ambient Temperatures below -10°C: use field wiring suitable for minimum ambient temperature

2. Cable entry devices and blanking elements shall be certified for protection type “d”; suitable for IP ratings and correctly
installed

3. Unused apertures shall be closed with suitable blanking elements

4. End User shall ensure adequate earthing or equipotential bonding is suitable for the installation of the metallic conduit

X3 Electronic Assembly
5. SUPPLY DISCONNECT DEVICE: End User shall provide a Supply Disconnect Device with the proper rating to comply with
IEC61010. The supply disconnecting device shall disconnect (isolate) the Electronic Enclosure / Actuator from the power
supply source when engaged.

6. TRANSIENT SUPPRESSION DEVICE: End user shall provide transient suppression of the supply terminals limiting to 140%
of the rated supply

7. Electronic enclosure shall be positioned such that the risk of impact to the window is low

8. CONDUIT ENTRY SEALS: End user shall seal all Electronic Enclosure ½” NPT and ¾” NPT conduit ports within 50.8mm [2.0”]
of entry using listed fittings and sealing compounds

9. FASTENERS: only M16X2.0X60MM Stainless Steel hex bolts are to be used

10. LITHIUM CELL: shall be replaced by certified REXA service personnel using only the following type of cell:

a. Rayovac BR2335, Lithium Carbon-Monofluoride (BR) Coin Cell. Rated 300mAh @ 3.0V. Operating Ambient: -40°C to 85°C

11. FUSE REPLACEMENT table is as follows:

FUSE REPLACEMENT TABLE

System Description Standard Fuse (A) Alternate Configuration Fuse (A) Fuse Type
D Module, 230 VAC 10 20
B Module, 115 VAC 6 10
C Module, 115 VAC 10 16
2C Module, 115 VAC 16 NA
1/2D Module, 230 VAC 10 20
Type ‘aM’; 500V, IR
1/2D Module, 115 VAC 20 32
120kA, 10mm x 38mm
B Module, 230 VAC 4 10
C Module, 230 VAC 6 12
2B Module, 230 VAC 10 NA
2C Module, 230 VAC 12 NA
2B Module, 115 VAC 10 NA

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 xi

X2 or X3 Actuator Assembly
12. CONDUIT ENTRY SEALS: End user shall seal all Actuator ½” NPT and ¾” NPT conduit ports within 457mm [18.0”] of entry
using listed fittings and sealing compounds

13. SURFACE CLEANING: Actuator Assembly includes a non-metallic outer protective coating which may be cleaned with a
damp cloth.

14. FASTENERS: shall be replaced only with the corresponding grade of fastener as follows:

ACTUATOR FASTENERS REPLACEMENT TABLE:

Stepper Motor Mounting Screws (secures motor to power module)
• US SHCS 1/4-20UNC-2A X 0.875
• Material is 18.8SS
• Min Yield Strength =207 Mpa [30ksi], Min Tensile Strength=517MPa [75ksi]
Servo Motor Mounting Screws (secures motor to power module)
• US SHCS 1/4-20UNC-2A X 1.25
• Material is 18.8SS
• Min Yield Strength =207 Mpa [30ksi], Min Tensile Strength=517MPa [75ksi]
Latch Cover Hex Bolt (secures threaded cover onto power module)
• US SHCS 1/4-20UNC-2A X 5/8
• Material is 18.8SS
• Min Yield Strength =207 Mpa [30ksi], Min Tensile Strength=517MPa [75ksi]

15. THREADED FLAMEPATHS: CUSTOMER TO ENSURE FINAL INSTALLATION COMPLIES WITH THE FOLLOWING TABLE:

Required Threads Design Thread Design Threads

FP # Flamepath Description Design Thread Thread Pitch Security Method
Engaged Length Engaged
Min: 14.78 Min: 5 ¼-20UNC-2A Socket Hex bolt
1,4 Threaded Cover 3.75-10UNS-2A 1/10UNC ≥5 with mechanical latch provided
Max: 15.24 Max: 6 on the power module
At least 5 threads to be fully
¾” and ½” NPT 3/4”-14 NPT Min: 12.24 Min: 11.76 engaged to internal NPT
3,6 Actuator Power 1/14 ≥5 threads on power module.
Module Entries 1/2”-14 NPT Max: N/A Max: N/A Internal threads gauge flush to
2 turns large with an L1 gauge

Product Compliance
 xii Product Compliance

SPECIFIC CONDITIONS OF USE (Zone 1) SIRA 17ATEX1231X

X3 Electronic Assembly
1. CONDUIT ENTRY SEALS: End user shall seal all Electronic Enclosure ½” NPT and ¾” NPT conduit ports within 50.8mm [2.0”]
of entry using listed fittings and sealing compounds

2. FASTENERS: only M16X2.0X60MM Stainless Steel hex bolts are to be used

3. LITHIUM CELL: shall be replaced by certified REXA service personnel using only the following type of cell:

a. Rayovac BR2335, Lithium Carbon-Monofluoride (BR) Coin Cell. Rated 300mAh @ 3.0V. Operating Ambient: -40°C to 85°C

X2 or X3 Actuator Assembly
4. CONDUIT ENTRY SEALS: End user shall seal all Actuator ½” NPT and ¾” NPT conduit ports within 457mm [18.0”] of entry
using listed fittings and sealing compounds

5. SURFACE CLEANING: Actuator Assembly includes a non-metallic outer protective coating which may be cleaned with a
damp cloth.

6. FASTENERS: shall be replaced only with the corresponding grade of fastener as follows:

ACTUATOR FASTENERS REPLACEMENT TABLE

Stepper Motor Mounting Screws (secures motor to power module)
• US SHCS 1/4-20UNC-2A X 0.875
• Material is 18.8SS
• Min Yield Strength =207 Mpa [30ksi], Min Tensile Strength=517MPa [75ksi]
Servo Motor Mounting Screws (secures motor to power module)
• US SHCS 1/4-20UNC-2A X 1.25
• Material is 18.8SS
• Min Yield Strength =207 Mpa [30ksi], Min Tensile Strength=517MPa [75ksi]
Latch Cover Hex Bolt (secures threaded cover onto power module)
• US SHCS 1/4-20UNC-2A X 5/8
• Material is 18.8SS
• Min Yield Strength =207 Mpa [30ksi], Min Tensile Strength=517MPa [75ksi]

7. THREADED FLAMEPATHS: CUSTOMER TO ENSURE FINAL INSTALLATION COMPLIES WITH THE FOLLOWING TABLE:

Required Threads Design Thread Design Threads

FP # Flamepath Description Design Thread Thread Pitch Security Method
Engaged Length Engaged
Min: 14.78 Min: 5 ¼-20UNC-2A Socket Hex bolt
3.75-10UNS-
1,4 Threaded Cover 1/10UNC ≥5 with mechanical latch provided
2A Max: 15.24 Max: 6 on the power module
At least 5 threads to be fully
¾” and ½” NPT 3/4”-14 NPT engaged to internal NPT
Min: 12.24 Min: 11.76
3,6 Actuator Power 1/14 ≥5 threads on power module.
Module Entries Max: N/A Max: N/A Internal threads gauge flush to
1/2”-14 NPT
2 turns large with an L1 gauge

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 xiii

SPECIFIC CONDITIONS OF USE (Zone 2) IECEx CSA 17.0013X

General
1. Ambient Temperatures below -10°C: use field wiring suitable for minimum ambient temperature

2. Cable entry devices and blanking elements shall be certified for protection type “d”; suitable for IP ratings and correctly installed

3. Unused apertures shall be closed with suitable blanking elements

4. End User shall ensure adequate earthing or equipotential bonding is suitable for the installation of the metallic conduit
X3 Electronic Assembly
5. SUPPLY DISCONNECT DEVICE: End User shall provide a Supply Disconnect Device with the proper rating to comply with
IEC61010. The supply disconnecting device shall disconnect (isolate) the Electronic Enclosure / Actuator from the power
supply source when engaged.

6. TRANSIENT SUPPRESSION DEVICE: End user shall provide transient suppression of the supply terminals limiting to 140% of
the rated supply

7. Electronic enclosure shall be positioned such that the risk of impact to the window is low

8. LITHIUM CELL: shall be replaced by certified REXA service personnel using only the following type of cell:

a. Rayovac BR2335, Lithium Carbon-Monofluoride (BR) Coin Cell. Rated 300mAh @ 3.0V. Operating Ambient: -40°C to 85°C

9. FUSE REPLACEMENT table is as follows:

FUSE REPLACEMENT TABLE:
System Description Standard Fuse (A) Alternate Configuration Fuse (A) Fuse Type
B Module, 115 VAC 6 10
B Module, 230 VAC 4 10
C Module, 115 VAC 10 16
C Module, 230 VAC 6 12 Type ‘aM’; 500V, IR
2B Module, 115 VAC 10 N/A 120kA, 10mm x 38mm
2B Module, 230 VAC 10 N/A
2C Module, 115 VAC 16 N/A
2C Module, 230 VAC 12 N/A
Standard: Type ‘aM’; 500V, IR 120kA, 10mm x 38mm
1/2D Module, 115 VAC 20 32
Alternate: Type ‘aM’; 400V, IR 120kA, 10mm x 38mm
1/2D Module, 230 VAC 10 20
Type ‘aM’; 500V, IR 120kA, 10mm x 38mm
D Module, 230 VAC 10 20
Dual 1/2D Module, 115 VAC 32 N/A Type ‘aM’; 400V, IR 120kA, 10mm x 38mm
Dual 1/2D Module, 230 VAC 20 N/A
Type ‘aM’; 500V, IR 120kA, 10mm x 38mm
Dual D Module, 230 VAC 20 N/A
D, P9, 230 VAC 25 N/A Type ‘aM’; 400V, IR 120kA, 10mm x 38mm
D, P40, 230 VAC 50 N/A Type ‘aM’; 690V, IR 120kA, 22mm x 58mm

Product Compliance
 xiv Product Compliance

X2 or X3 Actuator Assembly
10. SURFACE CLEANING: Actuator Assembly includes a non-metallic outer protective coating which may be cleaned with a
damp cloth.

11. FASTENERS: shall be replaced only with the corresponding grade of fastener as follows:

ACTUATOR FASTENERS REPLACEMENT TABLE:

Stepper Motor Mounting Screws (secures motor to power module)
• US SHCS 1/4-20UNC-2A X 0.875
• Material is 18.8SS
• Min Yield Strength =207 Mpa [30ksi], Min Tensile Strength=517MPa [75ksi]
Servo Motor Mounting Screws (secures motor to power module)
• US SHCS 1/4-20UNC-2A X 1.25
• Material is 18.8SS
• Min Yield Strength =207 Mpa [30ksi], Min Tensile Strength=517MPa [75ksi]
Latch Cover Hex Bolt (secures threaded cover onto power module)
• US SHCS 1/4-20UNC-2A X 5/8
• Material is 18.8SS
• Min Yield Strength =207 Mpa [30ksi], Min Tensile Strength=517MPa [75ksi]

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 xv

SPECIFIC CONDITIONS OF USE (Zone 2) SIRA 17ATEX4360X

General
1. Unused apertures shall be closed with suitable blanking elements

X3 Electronic Assembly
2. TRANSIENT SUPPRESSION DEVICE: End user shall provide transient suppression of the supply terminals limiting to 140%
of the rated supply

3. Electronic enclosure shall be positioned such that the risk of impact to the window is low

4. LITHIUM CELL: shall be replaced by certified REXA service personnel using only the following type of cell:

a. Rayovac BR2335, Lithium Carbon-Monofluoride (BR) Coin Cell. Rated 300mAh @ 3.0V. Operating Ambient: -40°C to 85°C

5. FUSE REPLACEMENT table is the same table used in the section above per Zone 2 certificate IECEx CSA 17.0013X.

6. FASTENERS: shall be replaced only with the corresponding grade of fastener as follows:

ACTUATOR FASTENERS REPLACEMENT TABLE:

Stepper Motor Mounting Screws (secures motor to power module)
• US SHCS 1/4-20UNC-2A X 0.875
• Material is 18.8SS
• Min Yield Strength =207 Mpa [30ksi], Min Tensile Strength=517MPa [75ksi]
Servo Motor Mounting Screws (secures motor to power module)
• US SHCS 1/4-20UNC-2A X 1.25
• Material is 18.8SS
• Min Yield Strength =207 Mpa [30ksi], Min Tensile Strength=517MPa [75ksi]
Latch Cover Hex Bolt (secures threaded cover onto power module)
• US SHCS 1/4-20UNC-2A X 5/8
• Material is 18.8SS
• Min Yield Strength =207 Mpa [30ksi], Min Tensile Strength=517MPa [75ksi]

Product Compliance
 xvi Product Compliance

EC Declaration Of Conformity
ACCORDING TO:
MACHINERY DIRECTIVE 2006/42/EC
EMC DIRECTIVE 2014/30/EC
We, REXA Inc.,

Hereby declare under our sole responsibility, the following products to be in compliance by design according to the relevant
essential health and safety requirements and harmonized standards mentioned. The Technical File may be produced by our EU
representative below. In case of alteration of the product, not agreed upon by us, this declaration will lose its validity.

Manufactured: 4 Manley Street

West Bridgewater, MA 02379 USA

EU Authorized Representative: Koso Kent Introl Limited Armytage Road, Brighouse, West Yorkshire HD6 1QF

Contact: Brian Richmond (QHSE Director) or Peter Dix (Technical Director)

Telephone: +44(0)1484 710311 Fax: +44(0)1484 407407

Brand Name:

Product Description: X-Pac, X2 and X3 Series Electraulic (Self-Contained Electro-Hydraulic) Actuator and Drive Systems

Models: Linear, Rotary and Drive Units

Servo or Stepper Units

Applicable Directives: Machinery Directive 2006/42/EC including Low Voltage Directive (LVD)

Electromagnetic Compatibility Directive (EMC) 2014/30/EU

Pressure Equipment Directive (PED) 2014/68/EU; applies where applicable, to accumulator systems

Radio Equipment Directive (RED) 2014/53/EU

RoHS Directive 2011/65/EU

Applicable Harmonized Standards:

Health/Safety: Machinery Directive 2006/42/EC Annex I, EN60204-1:2006, EN ISO 12100:2010, EN61310-1:2008,

EN61310-2:2008, EN ISO 13850:2015, IEC61010-1:2010

EMC: EN61326-1:2013, EN61000-6 Part -2:2005 and -4:2007; EN55011:2016: IEC61000-4-2:2008, IEC 61000-4-3:2010,
IEC61000-4-4:2012, IEC61000-4-5:2014, IEC61000-4-6:2013, IEC61000-4-8:2009, IEC61000-4-11:2004

PED: Directive 2014/68/EU; designed as ‘Sound Engineering Practice’ Equipment

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 xvii

EU Declaration of Conformity
According to: Directive 2014/34/EU

We, REXA Inc.,

Hereby declare under our sole responsibility, the following products to be in compliance by design according to the relevant
essential health and safety requirements and harmonized standards mentioned. The Technical File may be produced by our EU
representative below. In case of alteration of the product, not agreed upon by us, this declaration will lose its validity.

Manufactured: 4 Manley Street

West Bridgewater, MA 02379 USA

EU Authorized Representative: Koso Kent Introl Limited Armytage Road, Brighouse, West Yorkshire HD6 1QF

Contact: Brian Richmond (QHSE Director) or Peter Dix (Technical Director)

Telephone: +44(0)1484 710311 Fax: +44(0)1484 407407

Brand Name:

Product Description: Electraulic (Self-Contained Electro-Hydraulic) Actuator and Drive Systems; X3 Electronic Assembly
and X2 or X3 Actuator Assembly

Models: Linear, Rotary and Drive Units

Servo or Stepper Units

Designation: Ex db [ia IIC] IIB T3 -40C ≤ Ta ≤ 65C

Applicable Directives: Machinery Directive 2006/42/EC including Low Voltage Directive (LVD) 2014/35/EU

Electromagnetic Compatibility Directive (EMC) 2014/30/EU

Pressure Equipment Directive (PED) 2014/68/EU; applies where applicable, to accumulator systems

Radio Equipment Directive (RED) 2014/53/EU; applicable to optional Bluetooth feature

RoHS Directive EU 2015/863; met by design, by exclusion of hazardous / restricted substances

Applicable Harmonized Standards:

Health/Safety: Machinery Directive 2006/42/EC Annex I, EN60204-1:2006+A1:2009/AC 2010, EN ISO 12100:2010

EMC: EN61326-1:2013, EN61000-6 Part -2:2005 and -4:2007+A1:2011; EN55011:2009+A1:2010

ATEX: EN 60079-0:2012/A11:2013; EN 60079-1:2014; EN 60079-11:2011

PED: Directive 2014/68/EU; designed as ‘Sound Engineering Practice’ Equipment

Product Compliance
 xviii Product Compliance

EU Declaration of Conformity
According to: Directive 2014/34/EU

We, REXA Inc.,

Hereby declare under our sole responsibility, the following products to be in compliance by design according to the relevant
essential health and safety requirements and harmonized standards mentioned. The Technical File may be produced by our EU
representative below. In case of alteration of the product, not agreed upon by us, this declaration will lose its validity.

Manufactured: 4 Manley Street

West Bridgewater, MA 02379 USA

EU Authorized Representative: Koso Kent Introl Limited Armytage Road, Brighouse, West Yorkshire HD6 1QF

Contact: Brian Richmond (QHSE Director) or Peter Dix (Technical Director)

Telephone: +44(0)1484 710311 Fax: +44(0)1484 407407

Brand Name:

Product Description: X-Pac, X2 and X3 Series Electraulic (Self-Contained Electro-Hydraulic) Actuator and Drive Systems

Models: Linear, Rotary and Drive Units

Servo or Stepper Units

Designation: II 3G Ex nA II T3 Gc -40C ≤ Ta ≤ 65C Cert: SIRA 17ATEX4360X

Applicable Directives: Machinery Directive 2006/42/EC including Low Voltage Directive (LVD) 2014/35/EU

Electromagnetic Compatibility Directive (EMC) 2014/30/EU

Pressure Equipment Directive (PED) 2014/68/EU; applies where applicable, to accumulator systems

Radio Equipment Directive (RED) 2014/53/EU; applicable to optional Bluetooth feature

RoHS Directive EU 2015/863; met by design, by exclusion of hazardous / restricted substances

Applicable Harmonized Standards:

Health/Safety: Machinery Directive 2006/42/EC Annex I, EN60204-1:2006+A1:2009/AC 2010, EN ISO 12100:2010

EMC: EN61326-1:2013, EN61000-6 Part -2:2005 and -4:2007+A1:2011; EN55011:2009+A1:2010

ATEX: EN 60079-0:2012/A11:2013, EN 60079-15:2010

PED: Directive 2014/68/EU; designed as ‘Sound Engineering Practice’ Equipment

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 xix

Declaration of Noise Emission

The REXA inc., Incorporated Model REXA Electraulic™ Actuator System Sound Pressure Levels per EN ISO 11202 is as follows:

Year of Construction: 2017

Model No: As above Serial No: On Nameplate
Operating Idle
LpAm (Operator Position) 81 dB (A) 66 dB (A)
LpAm (Bystander Position) 84 dB (A) 67 db (A)
Peak C-weighted instantaneous SPL in the Operator’s position LpC peak 88 dB (c) --
Sound power emitted where the equivalent continuous A-weighted SPL exceeds 80 dB (A). 8.8 Bel --
The average difference between the extraneous noise level and the sound intensity level at
LpAm Δ= 16 dB (A)
each measuring point is:
Ambient Correction Factor K3A calculated according to EN ISO 11204 Appendix A. 4 dB(A)
Measurements were made at a height of 1.5 m and 1 m from the Operator Position and all four sides of the equipment.
The figures quoted are emission levels and are not necessarily safe working levels. While there is a correlation between the
emission and exposure levels this cannot be used reliably to determine whether or not further precautions are required.
Factors that influence the actual level of exposure of the workforce include characteristics of the work room, the other sources of
noise, etc. such as the number of machines and other adjacent processes. Also, the permissible level of exposure can vary from
country to country.
This information, however, will enable the user of the machine to make a better evaluation of the hazard and risk.

REXA Inc.
4 Manley Street
West Bridgewater, MA USA

Product Compliance
 xx Product Compliance

Waiver Of Translations Agreement

We, REXA Inc.,

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

• Installation and Operation Manual (IOM)

• Interconnect, layout and wiring schematics and drawings

• Technical Service and Repair Manual

This document also waives the responsibility of translations of the following system components and markings:

• Human Machine Interface (HMI Keypad Display) textual read-out of system parameters and status display

• Modification of keypad display symbols to ISO characters

• Internal labeling and identification symbols and statements

• Individual wire and component marking identification is not required. The fully assembled factory wired panel is only
serviced by REXA personnel and not the end user. However, end - user terminations are readily identified.

Translations of the above mentioned may be made by the end user and/or the authorized representative listed on this document.
Any of which may be translated must bear the statement ‘Translation of Original Instructions’ within the document(s) header or
footer.

EU Authorized Representative: Koso Kent Introl Limited Armytage Road, Brighouse, West Yorkshire HD6 1QF

Contact: Brian Richmond (QHSE Director) or Peter Dix (Technical Director)

Telephone: +44(0)1484 710311 Fax: +44(0)1484 407407

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 xxi

Waiver of Main Supply Disconnect/Emergency Stop Agreement

We, REXA Inc.,

Hereby declare it the responsibility of the installer of this equipment to provide a suitable disconnect for the Control Panel supplying
power to the system.

The disconnect must:

• Be suitable for the Voltage and Full Load Ampere Rating of all downstream equipment supplied by the Panel;

• The supply disconnecting device shall be one of the following types:

○ Switch-disconnector with fuses, in accordance with IEC 60947-3, utilization category AC-23B or DC-23B

○ As above, except one that has an auxiliary contact that in all cases causes switching devices to break the load circuit
before the opening of the main contacts of the disconnector.

○ A circuit breaker suitable as an isolation device per IEC 60947-2

○ Any other switching device in accordance with an IEC product standard that also meets the isolation requirements of
IEC 60947-1 and is appropriate for on-load switching of the largest motor or other inductive loads;

• Be approved for use as a disconnect for the country in which the system is installed.

• Be provided with a Lock Out Tag Out capability in the Off (Down) position.

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

If assistance is required in specifying an appropriate device, please contact our engineering department for recommendations.

Product Compliance
 1 1. General Information

1 General Information

1.1 About REXA

REXA is located in West Bridgewater, Massachusetts, USA. We manufacture, sell and service the highest quality actuators and drives.
The driving force of these units is a self-contained electrically driven hydraulic pumping system, thus the term Electraulic™ is coined.
This Installation and Operation Manual is part of REXA’s continuing commitment to supply only the highest quality products and
services to our customers. Customer support is our top priority at REXA.

Please contact the factory if this manual, or your Sales Representative, fails to provide required information.

1.2 Factory Support

REXA is a full service company. We have a fully staffed service department with factory trained and certified service personnel for both
factory and on site repair. For repair, service, sales, warranty or parts order, you may contact the factory at the following REXA, Inc.

4 Manley Street Phone: (508) 584-1199

West Bridgewater, MA 02379 Web: www.rexa.com

Note: It is important to have the model code and serial number for both the electronics and the actuator in addition to the serial number
for the actuator so we can provide better service.

This information can be found on the metal tags on the actuator and on the front panel of the electronics. Reference the sections
below on Actuator Identification for more detailed explanation.

1.3 Actuator Identification

The model number, mechanical build number, electronics build number and serial numbers are all used to identify an individual
actuator and electronics.

The model number will provide a general description of the actuator and electronics as a set. These numbers also provide the
information required to correctly define what sections of this manual applies to a particular actuator. The build number provides
more detailed information of the components used in the construction of the actuator. Finally the serial number will allow the
factory to determine any special considerations or features your actuator may have that make it unique.

Since most applications are custom, this is the only identification that fully allows us to identify the unit. The factory requires these
numbers whenever service or information is requested. Supplying the model, both mechanical and electrical build numbers, and
the serial number will ensure the quickest and most accurate response to your request. These numbers can be found on the ID tags
located on the actuator and on the serial tag on the electronics. Figure 1.3 shows a typical ID tag.

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 2

4Manleystreet

� W. Bridgewater, MA

MODELIMODEL NUMBER DESCRIPTION I

USA (508) 584 • 1199

SERIAL I SERIAL NUMBER I BUILD I BUILD CODE I

INPUT IVOLTAGE IIAMPS PHASE HERTZ 11 11 I
0 ICUSTOMER SPECIFIC TAG INFO IINEMA 10
APPROVAL CSA CLASSIFICATION MULTIPLE RATED EQUIPMENT,
LOGOS I HAZLOC TEMP RATINGS 11 REFER TO X3 INSTALLATION &
MECHANICAL OUTPUT
OPERATION MANUAL
MECHANICAL TRAVEL

WARNINGS AND/OR AREA DESIGNATIONS

Figure 1.3 ID Tag

1.3.1 Model Number
The basic model number is a generic description of the actuator. Figure 1.3.1 shows a break down of the model number tree and
how it works.

MODEL NUMBER
X3__ __ __ __ __ – __ __ – __ – __-__
Thrust –Stroke
Series 3 Torque –Rotation Fail Safe Options Hazardous Area Code
(Upon Power Loss)
L Series – Xpac Linear C1: Division 1 / Zone 1
P: None – Lock in Place
R Series – Xpac Rotary Actuator Only
U: Universal (Rotary)
D Series – XPac Drive C2: Division 2 / Zone 2
E: Extend (Linear)
Actuator and Electronics
R: Retract (Linear)
C5: Division 1 / Zone 1
L SERIES A: Accumulator Failure
Actuator with Division 2 /
Thrust Strokes Zone 2 Electronics
(lbf·in) (degrees) R or D SERIES C6: Division 1 / Zone 1
2000 –.75, –2, –4 –6, –8, –11 Torque Rotation Power Modules Actuator and Electronics
4000 –.75, –2, –4 (lbf·in) (degrees) CA: Division 2 / Zone 2
B: Single B
5000 –.75, –2, –4, –6, –8, –11, –16, –22 2500 –90, –120 Actuator Only
C: Single C
10000 –.75, –2, –4, –6, –8, –11, –16, –22 5000 –90, –120 ½D: Single ½D
15000 –.75, –2, –4, –6, –8, –11, –16, –22 10000 –90, –120 D: Single D
20000 –.75, –2, –4, –6, –8, –11, –16, –22 20000 –90, –120 2C: Dual C Manifold
30000 –.75, –2, –4, –6, –8, –11, –16, –22 50000 –90, –120 2D: Dual D Manifold
100000 –90, –120 D,P9: Booster Pump
40000 –.75, –2, –4, –6, –8, –11, –16, –22
D,P20: Booster Pump
50000 –.75, –2, –4, –6, –8, –11, –16, –22 200000 –90, –120
D,P40: Booster Pump
60000 –.75, –2, –4, –6, –8, –11, –16, –22 400000 –90, –120
80000 –.75, –2, –4, –6, –8, –11, –16, –22
120000 –.75, –2, –4, –6, –8, –11, –16, –22

Figure 1.3.1 Model Number

1. General Information
 3 1. General Information

Model Numbers — Examples:

X3L4000-4-C-P X3R2500-90-B-U
Is a Linear L Xpac Series 3 with 4 000 lb of thrust, stroke A Rotary R Xpac Series 3 with 2 500 lbf·in of torque, rotation
adjustable up to 4 inches, and C size power module. Lock in adjustable to 90 degrees, and B size Power module. Spring
position upon loss of power. failure upon loss of power.
1.3.2 Serial Number
Serial numbers are assigned to every job at REXA. Job specific information as well as sales and engineering information are stored
under a specific serial number. A typical serial number will look like: RC1800000. The RC1 indicates the year of manufacture and the
next four digits correspond to the unique order number.

1.3.3 Build Number

The build number is a catalog number we use to designate in complete detail the construction of the actuator. From this number all
configurations can be defined. There are two different categories of build numbers; one is for the mechanical sub-assembly, and the
second is for 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.

1.4 General Specifications

1.4.1 Recommended Fluids and Lubricants

Intended Use Specifications

Operating fluid, all REXA Actuators Castrol EDGE® SAE 5W-50 Motor Oil
Anti-Seize Compound Bostik Never-Seez® or equivalent
O-ring Lubricant Parker Super-O-Lube or equivalent
Thermal Grease Thermalcote™ or equivalent
Molybdenum Disulfide Grease Mobilgrease® XHP 222 or equivalent
Parts Cleaner ZEP® BRAKE WASH or equivalent

1.4.2 Operating Temperatures

The following is a general guideline.
Table 1.4.2-1 Linear Actuators
Actuator
Standard High Temp.
Construction
Temperature Range¹

Type L Linear -5 °F to +200 °F -30 °F to +200 °F

‡
-76 °F to +200 °F -5 °F to +250 °F
Cylinder (-20 °C to +93 °C) (-34 °C to +93 °C) (-60 °C to +93 °C) (-20 °C to 121 °C)
Type C Linear +10 °F to +200 °F -10 °F to +200 °F -76 °F to +200 °F -5 °F to +250 °F
Cylinder (-12 °C to +93 °C) (-23 °C to +93 °C) (-60 °C to +93 °C) (-20 °C to 121 °C)
Installation 1 inch thermal Heat tracing & 1 inch
None None
Requirements insulation 2 thermal insulation 2
Electronics Separate Control Enclosure with CPU, motor driver, power supply, transient protection and termination.
Temp. Range -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.

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Xpac Series 3 - Installation and Operation Manual - 9/22 4

Table 1.4.2-2 Rotary Actuators & Drives

Actuator
Temperature Range1

Standard High Temp.

Construction
Type R Rotary or +10 °F to +200 °F -10 °F to +200 °F -76 °F to +200 °F -5 °F to +250 °F
D Drive Cylinder (-12 °C to +93 °C) (-23 °C to +93 °C) (-60 °C to +93 °C) (-20 °C to +121 °C)
Installation Standard oil & 1” of thermal Heat tracing & 1”
Optional High Temp. Construction
Requirements cartridge heater insulation 2 therm 2
Electronics Separate Control Enclosure with CPU, motor driver, power supply, transient protection and termination.
Temp. Range -40 °F to +140 °F (-40 °C to +60 °C) -40 °F to +120 °F (-40 °C to +50 °C)
Motor Type Stepper Servo
Table 1.4.2-3 CSA Temperature Ratings
Operating Temperatures
Power Module Duty* Cycle Notes
Actuator Electronics
B, 115Vac -40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +140 °F (-40 °C to +60 °C) S1
B, 230Vac -40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +104 °F (-40 °C to +40 °C) S1
C, 115Vac -40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +140 °F (-40 °C to +60 °C) S1
C, 230Vac -40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +104 °F (-40 °C to +40 °C) S1
2C, 115Vac -40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +140 °F (-40 °C to +60 °C) S1
.5D, 115Vac -40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +150 °F (-40 °C to +65 °C) S1
.5D, 230Vac -40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +150 °F (-40 °C to +65 °C) S1
D, 230Vac -40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +131 °F (-40 °C to +55 °C) S1
Dual .5D, 115Vac -40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +150 °F (-40 °C to +65 °C) S1
Dual .5D, 230Vac -40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +150 °F (-40 °C to +65 °C) S1
2D, 230Vac -40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +131 °F (-40 °C to +55 °C) S1
D,P9, 230Vac -40 °F to +140 °F (-40 °C to +60 °C) -40 °F to +122 °F (-40 °C to +50 °C) S8 1, 2
D,P20, 230Vac -40 °F to +140°F (-40 °C to +60 °C) -40 °F to +122 °F (-40 °C to +50 °C) S8 1, 2
D,P40, 230Vac -40 °F to +140°F (-40 °C to +60 °C) -40 °F to +122 (-40 °C to +50 °C) S8 1, 2

Notes
1. Duty cycle for D,P9, D,P20, or D,P40 power module motor is S1, booster motor will remain S8.

2. Uses 48 Vdc to 72 Vdc converter.

S1 Duty cycle S1 is defined as continuous operation at load.

S8 Duty cycle S8 is defined as periodic duty with rest period between operation, variable load/speeds.

*Duty Cycle definitions taken from IEC 60034-1 applies to all rotating electrical machines.

1. General Information
 5 1. General Information

1.4.3 Relative Humidity

The equipment will operate correctly within an environment at 50% RH, +40 °C (+104 °F). Higher RH may be allowed at lower temperatures.

Measures shall be taken by the Purchaser to avoid the harmful effects of occasional condensation.

1.4.4 Transportation and Storage

This equipment will withstand, or has been protected against, transportation and storage temperatures of −25 °C (−13 °F) to +55 °C
(+131 °F) and for short periods up to +70 °C (+158 °F).

It has been packaged to prevent damage from the effects of normal humidity, vibration and shock.

1.5 Maintenance Schedule

The REXA actuator requires minimal routine maintenance consisting primarily of visual inspections. As with any mechanical
device, components will wear over time. The frequency of use and the operating conditions are both factors that will dictate the
maintenance schedule.

Note: With time and experience, a predictable schedule of maintenance and replacement of seals may be developed.

Quarterly
Perform a visual inspection of the actuators for damage, correct oil level, 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:

• Visual inspection for damage

• Oil level is correct

Note: Ambient temperature swings will affect the oil indicator position.

• Tubing and fittings are tight, not touching or rubbing

• Mounting hardware and fasteners are tight

• Record system stats (strokes, error codes and gauge pressures)

1.6 Oil
1.6.1 Oil Level Inspection
The REXA Xpac Actuator is a sealed, self-contained, hydraulic positioning system in which oil is pumped from one side of a double acting
cylinder to the other. A thermal expansion chamber provides a source of make up oil for the flow matching valve and is an integral
component within the module. As the size of the actuator cylinders increase so does the need for additional make up oil, therefore
larger systems will have external auxiliary expansion chambers in addition to the standard internal thermal expansions chamber .

A closed-loop hydraulic system means that the oil in the actuator is isolated from the environment and immune to degradation with
time as a result of exposure to moisture and other atmospheric elements. Since the hydraulic system is sealed and spring-loaded, it
is also unaffected by the orientation in which the actuator is applied.

A periodic, visual inspection of the REXA Xpac Actuator is required in order to verify that the hydraulic system has not been
compromised for any reason. Any external signs of a major oil leak or repeated refilling of the unit will indicate damage to the
actuator that will require servicing of the unit and investigation for a cause.

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Xpac Series 3 - Installation and Operation Manual - 9/22 6

Auxiliary Expansion Chamber Settings Thermal Expansion Chamber Settings

With the accumulator fully discharged, the With the accumulator fully discharged, the
accumulator pressure gauge must read 0 PSI. Fill accumulator pressure gauge must read 0 PSI. Fill
until indicator extension is until thermal expansion chamber pressure is
XXX ±½” XXX ±5 PSI
WARNING: Adding oil to the unit without WARNING: Adding oil to the unit without
verifying the accumulator is at 0 PSI before filling verifying the accumulator is at 0 PSI before filling
will cause damage and potential injury or death. will cause damage and potential injury or death.
When the accumulator is full @ XXX PSI. The When the accumulator is full @ XXX PSI. The
indicator extension should be @ XXX ±½” thermal expansion pressure should be @ XXX ±5 PSI

1.6.2 Standard Units

There is an oil level indicator on the actuator body located on the same face as the motor shown in Figures 1.6.2-1—1.6.2-3. It is
used to display the oil level within the actuator. The indicator is a silver rod with a scale beside it reading “Hot”, “Ok” and “Add”. As
the unit cools down and heats up the indicator will move in and out. At 70 °F the indicators ideal position will be in the middle of the
“Ok” region. The unit may be indicating near the “Add” limit if the ambient temperature is lower and will indicate in the “Hot” region
if the ambient temperature is elevated. The thermal expansion chamber volume has been sized for 110 °F temperature swings.
Reference Figures 1.6.2-1 through 1.6.2-3 showing the different indication levels.

Figure 1.6.2-1 Add oil indication Figure 1.6.2-2 Full oil indication Figure 1.6.2-3 Oil Expansion

Larger units will require additional make up oil and an external auxiliary expansion chamber will be plumbed in series with the
internal thermal expansion chamber. The internal thermal expansion chamber will still show the oil level however there is also an
indicator rod in the external auxiliary expansion chamber. At an ambient condition of 70 °F it should be protruding out approximately
3-½ inches as measured from the base of the bushing shown in Figure 1.6.2-4.

Figure 1.6.2-4 External Auxiliary Expansion Chamber

1. General Information
 7 1. General Information

1.6.3 Accumulator Fail

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

In order to check the level of the oil in an accumulator system you must locate the “Auxiliary Expansion
Chamber Settings” label shown below. This can be found on the accumulator bottle.

The accumulator bottle can be checked when the accumulator is fully charged or fully discharged.
Compare the actuator condition to the proper settings listed on the accumulator bottle labels. Figure 1.6.3 Accumulator
Reference section 1.6.4 and add oil if necessary. Pressure Gauge
1.6.4 Filling
If the addition of oil is required, it should be filled with Castrol EDGE® SAE 5W-50 motor oil (Figure 1.6.4-1). An unusual application may
require different oil. (Refer to the actuator serial plate.) The actuator does not need to be taken out of
service when adding oil.

Note: Although Castrol Edge oil is recommended, oil of equal quality may be used.

REXA Xpac Actuators are filled through a standard Schrader-style Fill Valve located on the power module.
Use any oil gun equipped with a Schrader-style fitting. The mating half of a Schrader-style fitting can be
obtained at any auto parts store, purchased through a REXA Sales Rep, or purchased directly from REXA’s
Inside Sales Office. The following steps will guide a user to successfully fill a REXA Xpac Actuator with oil:

Note: Do not overfill the thermal expansion chamber. While overfilling will not harm the actuator on non-
accumulator units, overfilling will force oil from the thermal expansion chamber. Overfilling will also promote
oil weeping from the overfill protection due to thermal expansion. If an accumulator unit is overfilled, the
reservoir can be over pressurized and catastrophic seal damage can occur.

PROCEDURE (9 steps):
1. Locate and Remove the fill valve cover (Figure 1.6.4-2). Figure 1.6.4-1 Castrol EDGE

Figure 1.6.4-2 Fill Valve with cover.

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

Figure 1.6.4-3 Fill the oil gun.

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Xpac Series 3 - Installation and Operation Manual - 9/22 8

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

Figure 1.6.4-4 Purge the air.

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

Figure 1.6.4-5 Oil Pump Valve.

5. Attach the oil fill gun to the actuator’s Schrader fitting (Figure 1.6.4-6).

Figure 1.6.4-6 Fill Valve with Schrader fitting.

6. Add oil until the indicator is in the “OK” section of the scale (Figure 1.6.2-2). Reference the accumulator bottle labels for
correct filling of Accumulator units.

7. Remove the oil gun from the Fill Valve.

8. Re-install the fill valve cover.

9. Drain and store the Fill Gun in a clean place for future use.

1. General Information
 9 1. General Information

1.6.5 Overfilling, Oil Weeping, and Thermal Expansion

All REXA Xpac Actuators contain a Thermal Expansion Valve located next to the Schrader-style Fill Valve. If an actuator is overfilled with
oil, it should be expected that oil will purge out of the Thermal Expansion Chamber. Simply wipe-off whatever oil may be purged.

The thermal expansion valve is built into every REXA Xpac Actuator in order to allow the actuator to relieve the chamber of excess
oil pressure due to thermal expansion. Thermal expansion refers to the volumetric changes a fluid, such as oil, experiences given
changes in environmental temperature.

It is not uncommon to discover trace amounts of residual oil collected around the thermal expansion chamber of an valve if the unit
has been overfilled. This residual oil is typically the result of oil weeping from the overfill protection as the ambient temperature
increases causing the oil to expand. As previously mentioned, the actuator is a closed-loop hydraulic system, and any increase in oil
volume will be purged. On large oil volume actuators REXA adds an external auxiliary expansion chamber in order to compensate
for the greater volume of oil that may expand due to increases in ambient temperature.

If the temperature is lowered, the auxiliary expansion chamber indicator will retract as the oil volume decreases. Oftentimes, users will
mistake the indicator retraction as a sign that the actuator has lost oil due to a service issue. If a user adds oil to the actuator at this time,
oil will likely purge out of the Thermal Expansion Valve upon an eventual rise in ambient temperature. It is when oil is evidently leaking,
or collected in large amounts somewhere on, or dripping off, a REXA Xpac Actuator that a service-related issue is likely, and oil filling is
needed. For this reason, we ask users to perform periodic inspections with ambient temperature changes in mind.

1.6.6 Air Purging

As previously noted, all REXA Xpac Actuators are characterized by a closed-loop, hydraulic system that is responsible for their
distinguished reputation as being unmatched in rigidity, precision and control. This is, in part, due to the advantages of using
hydraulics in place of pneumatic actuation. Air is a compressible medium that results in many inherent disadvantages, such as poor
control and rigidity, when used in actuation.

In light of these facts, it is obvious that the presence of any air in the closed-loop hydraulic system of a REXA Xpac Actuator is extremely
disadvantageous and detracts from performance of the actuator. Certain repair and replacement procedures will involve exposing the
internal hydraulic system to the outside environment and may introduce unwanted air to the system. The presence of air in the hydraulic
system is likely to cause problems such as unstable positioning. For this reason, whenever the closed-loop hydraulic system of a REXA
Xpac Actuator is opened to the atmosphere, it is imperative that necessary steps are taken to remove any air from the system. When
purging a REXA Xpac Actuator of air, there are two main areas of concern: the thermal expansion chamber and the hydraulic system.

1.6.7 Thermal Expansion Chamber Purging

Figure 1.6.7-1 Purge Ports

1. It is important to first identify if the chamber has entrapped air. This can be done by pressing in on the oil level indicator. If
it does not feel “stiff,” there is air in the chamber.

Note: Be aware of external thermal expansion chambers or additional modules; press evenly on all indicators to check for entrapped air.

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 10

2. Depending on the orientation of the actuator the highest purge point on the module must be identified, as any entrapped
air will migrate to the highest point. Purge Port 1 and Purge Port 2 (Figure 1.6.7-1) are both at corners of the thermal
expansion chamber volume and most likely will be the highest points.

Figure 1.6.7-2 Full Indicator “OK”– flush with front face

3. Slowly unthread the highest purge point fastener and have an oil catch pan ready. It may not be necessary to fully remove
these plugs as air will purge out with a few threads still installed.

Note: Some modules will have external thermal expansion chambers attached and the plugged ports may be the highest points.

4. Retighten the plug before proceeding.

5. Refill to the correct oil level.

Note: Some actuator orientation will not allow for proper purging and the actuator may need to be removed and re-orientated
for purging, then re-installed. The best position for purging is with purge port 1 facing up.

1.6.8 Hydraulic System Purging

To purge the actuator of air, it is recommended that you use the REXA bleed kit. See Figure 1.6.8-2 for details.

1. Change the Max Man Spd to 30% or less. (Refer to section 6.1.5.)

Figure 1.6.8-1 Extend/CW and Retract/CCW Ports

2. Open the manual bypass to relieve internal pressure. (Refer to C1.4.)

Note: Some units can have a solenoid instead of a manual bypass; ensure that the solenoid is open before proceeding.

1. General Information
 11 1. General Information

Figure 1.6.8-2 Bleed Kit (PN: K09275)

3. Locate the best available pressure ports to bleed air from the system. The best position is the highest point that is accessible
and will allow air to escape the system. Keep in mind that the porting may be located on the module, cylinder, manual
hydraulic pump or SCL, etc.

4. Attach the REXA bleed kit (Figure 1.6.8-2) to the open ports Extend/CW and Retract/CCW. Follow the hydraulic lines to
differentiate between pressure direction (Figure 1.6.8-1).

5. Run the actuator through its full stroke constantly pumping oil into the thermal expansion chamber. Do not let the
chamber run dry, or you will need to purge the chamber and start over.

1.7 Tool Requirements (Power Module Only)

All these common tools may be required during installation and maintenance:

• Flashlight • Snap Ring Pliers • Soft Blow Hammer • 3/8 ˝ Nut Driver
• Standard Set of Allen Wrenches • Wire Strippers • Set of Flat Tip Screwdriver • Needle Nose Pliers
• Set of Picks • Crimper • Set of Combination Wrenches • Wire Cutter
• 3/16 ˝ Nut Driver • Oil Gun with Schrader Fill Assembly • 12 ˝ Channel Lock Pliers • Digital Volt Meter

1.8 Theory Of Operation

1.8.1 Overview
The REXA Xpac is a microprocessor controlled, self-contained, Electraulic™ (electro-hydraulic) actuator or drive designed specifically for
modulating service. Hydraulic, electronic and mechanical technologies are combined to achieve REXA’s state-of-the-art line of actuators.

The patented Flow Match System is simply described as a highly efficient method of pumping hydraulic fluid (motor oil Castrol
EDGE® SAE 5W-50) from one side of a double acting cylinder to the other. Once the correct position is reached, the motor shuts off.
Power is not required to maintain actuator position. The hydraulics are controlled by a dedicated microprocessor contained within
the control enclosure. Software designed for the Xpac allows the user to set actuator operation parameters.

Note: Although Castrol Edge oil is recommended, oil of equal quality may be used.

The Xpac consists of two major components, the actuator (cylinder, feedback and Electraulic power module) and the control
enclosure. The actuator is installed on the driven device, while the enclosure is remotely mounted. Connecting the actuator and
enclosure are the module cable and the feedback cable.

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1.8.2 Actuator
The heart of the actuator is the Electraulic Power Module. Consisting of a motor, gear pump, flow match valve (FMV), make-up oil thermal
expansion chamber, heater, thermostat and bypass solenoid (spring fail units only), the Power Module delivers oil at a nominal 2000
psi to a hydraulic cylinder. Four different size modules, B, C, ½D and D, are available meeting hazardous area but non-explosion proof
requirements. For applications requiring hazardous area and explosion proof approvals, two different power modules, C and D are
available. The major functional difference between the sizes is pumping volume and thus, the maximum stroking speed of an actuator.

The B and C modules are driven with a stepper motor and therefore have a slower frequency response then the D series modules
which are driven with servo motors. More detailed information on the frequency response and flow rates can be found in product/
technical memos. The only visible difference among all 4 sizes of modules is the motor.

There are three types of hydraulic cylinders. On smaller size linear actuators (thrust of 10 000 lb or less and strokes of 6 inches or
less), the L series cylinder is manufactured from a solid block of aluminum. Larger size C series cylinders are made of a fabricated
tie-rod construction. The third type, used on rotary (series R) and drive (series D) units, is a rack and pinion rotary design.

A position sensor, provides feedback position to the control electronics. The feedback assembly is sealed in a NEMA 4X cover and
mounted within or adjacent to the cylinders. The connection of the position sensor is by direct mechanical means.

The B and C modules shown in Figure 1.8.2-1&2 are the two sizes of stepping motor modules. They both have cylindrical motor
cases. The motor case lengths are depicted in Figure 1.8.2-1&2 for module identification purposes. With the exception of pump and
motor size, these two modules share many of the same components so both modules will be depicted on one rebuild diagram for
each of the applicable service sections.

Figure 1.8.2-1 B Module

Figure 1.8.2-2 C Module

The 1/2D and D modules shown in Figure 1.8.2-3&4 are the two sizes of servo motor modules. They both have square case motors.
The motor case lengths are depicted in Figure 1.8.2-3&4 for module identification purposes. Again, with the exception of pump and
motor size, these two modules share many of the same components so both modules will be depicted on one rebuild diagram for
each of the applicable service sections.

1. General Information
 13 1. General Information

Figure 1.8.2-3 1/2D Module

Figure 1.8.2-4 D Module

The C and D explosion proof modules shown in Figure 1.8.2-5&6 are two sizes of power modules offered for applications requiring
hazardous area and explosion proof approvals. The motor case lengths are depicted in Figure 1.8.2-5&6 for module identification
purposes. With the exception of pump, motor size, and cover, these modules share many of the same components as the non-
explosion proof modules so both modules will be depicted on one rebuild diagram for each of the applicable service sections.

Figure 1.8.2-5 C Module

Figure 1.8.2-6 D Module

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1.8.3 Control Sub-Assembly

The control sub-assembly consists of the enclosure, CPU, power supply, motor drivers, main Power Transient Suppression, and a
termination area.

The control sub-assembly also provides the user interface. The enclosure mounted 4-line x 20 character/line Vacuum Fluorescent Display
(VFD) with Limited Graphics and 5 button keypad will be the point for setup and calibration of the actuator as well as visual feedback of
actuator status. The Keypad and Display can be optionally mounted inside the Control Enclosure should the installation warrant it.

The CPU consists of a microprocessor, an analog-to-digital (A/D) converter, an isolated 4-20 mA position transmitter, electronic limit
switches, as well as warning and alarm relays. The CPU will also accept optional I/O interface boards.

The power supply develops DC voltages from the incoming AC power. The DC voltages, +5, +15 and +24 Vdc, provide power to the
CPU, actuator feedback circuit, the optional interface boards as well as optional loop supply (+24 Vdc) for the Position Transmitter.

The motor driver is the component that supplies power to the motor. It can either be a DC Stepper Motor Driver or an AC Servo
Motor Driver, depending on the model actuator. The motor driver accepts command signals from the CPU and provides DC Step
Pulses (Stepper Motor) or Pulse Width Modulated (PWM) DC Voltage (Servo Motor) to the module mounted motor to drive it in one
direction or the other. There is one motor driver for each power module.

Refer to Tables 1.8.3-1 and 1.8.3-2 for Terminal Block ratings.

Figure 1.8.3 Typical Control Enclosure

316 Stainless-Steel Enclosure Specifications For Single Module Actuators:
• UL 508 Types 12, 4

• CSA Type 12, 4

• Complies with NEMA Type 12 and 4X

• IEC 529, IP66 Construction

1. General Information
 15 1. General Information

1.8.4 REXA Terminal Blocks

Low Power Terminal Block
Connection Description: CPU connections/ Resolver/ Solenoids/ Heater/ Stepper Motor Power

Physical:
• Single level, feed-thru connector

• Operating Temperature: -40°F to 221°F (-40°C to 105°C)

• Insulating Material: PA (polyamide)

• Inflammability Rating: UL94V0

• Color 1: Gray (standard terminal)

• Color 2: Green/Yellow (ground terminal)

Connections:
• Screw Thread: M3

• Wire Range: 26 to 10 AWG (0.14mm2 to 6.0mm2)

• Tightening Torque: 5.31 in-lbs. to 7.08 in-lbs. (0.6Nm to 0.8Nm)

• Stripping Length: 0.35” (9mm)

Electrical:
• Voltage Rating: 600V

• Current Rating: 30A

Figure 1.8.4-1 Low Power Terminal Block

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 16

Medium Power Terminal Block

Connection Description: Servo Motor and P9 Booster Motor Power

Physical:
• Single level, feed-thru connector

• Operating Temperature: -40°F to 221°F (-40°C to 105°C)

• Insulating Material: PA (polyamide)

• Inflammability Rating: UL94V0

• Color 1: Gray (standard terminal)

• Color 2: Blue (neutral terminal)

• Color 3: Green/Yellow (ground terminal)

Connections:
• Screw Thread: M4

• Wire Range: 24 to 8 AWG (0.2mm2 to 10.0mm2)

• Tightening Torque: 13.27 in-lbs. to 15.93 in-lbs. (1.5Nm to 1.8Nm)

• Stripping Length: 0.39” (10mm)

Electrical:
• Voltage Rating: 600V

• Current Rating: 50A

Figure 1.8.4-2 Medium Power Terminal Block

1. General Information
 17 1. General Information

High Power Terminal Block

Connection Description: P40 Booster Motor Power

Physical:
• Single level, feed-thru connector

• Operating Temperature: -40°F to 221°F (-40°C to 105°C)

• Insulating Material: PA (polyamide)

• Inflammability Rating: UL94V0

• Color 1: Gray (standard terminal)

• Color 2: Green/Yellow (ground terminal)

Connections:
• Screw Thread: M6

• Wire Range: 18 to 1/0 AWG (0.75mm2 to 50.0mm2)

• Tightening Torque: 28.32 in-lbs. to 33.63 in-lbs. (3.2Nm to 3.7Nm)

• Stripping Length: 0.63” (16mm)

Electrical:
• Voltage Rating: 600V

• Current Rating: 50A

Figure 1.8.4-3 High Power Terminal Block

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 18

High Power Terminal Block

Physical (Plug):
• 24 position female plug with dual-entry port hub

• Operating Temperature: -40°F to 257°F (-40°C to 125°C)

• Insulating Material: PA (polyamide)

• Contacts: Silver plated copper alloy

• Inflammability Rating: UL94V0

Connections (Plug):
• Screw Thread: M6

• Wire Range: 20 to 14 AWG (0.5mm2 to 2.5mm2)

• Tightening Torque: 4.42 in-lbs. to 7.08 in-lbs. (0.5 Nm to 0.8 Nm)

• Stripping Length: 0.32” (8mm)

Physical (Hub):
• Housing Material: Aluminum, die-cast

• Operating Temperature: -40°F to 257°F (-40°C to 125°C)

• Surface Material: Powder coated, gray

• Locking Screw Material: Stainless steel

• Protection: IP66, NEMA 4X

Connections (Hub):
• Screw Thread: Phillips screw

• Tightening Torque: 26.55 in-lbs. (3.0 Nm)

Electrical:
• Voltage Rating: 600V

• Current Rating: 16A

Figure 1.8.4-4 Female Plug Pinout Connection

1. General Information
 19 1. General Information

Figure Recommended Installation Practices

1. Remove female plug from hub by loosening the four screws to gain access to wire termination screws.

2. Signal level connections will use the M25 entry port: these are identified in red highlight in the table above

3. Power level connections will use the M32 entry port

4. It is critical to use separate conduits for signal and power to eliminate noise interference

5. REXA offers M32 to 1” NPT adaptors and M25 to¾ “ NPT adaptors

6. Wire connections to female plug per pinout table above

7. Strip wires and torque connections per specifications

8. Re-attach female plug by tightening the four screws to hub

9. Tightly secure the entry port conduits and apply Loctite

10. Torque the top and bottom hub screws per specification to maintain IP rating of the hub

Note: images below show a female plug mounted within hub, the actual number of positions is not shown. The correct terminal hub
installation requries separate conduits entries for power wiring and signal wiring

Figure 1.8.4-5 Wire Termination Hub

Table 1.8.4-1 Control Enclosure Terminal Blocks Table 1.8.4-2 Actuator Terminal Blocks
Mechanical Mechanical
Termination Torque 10 lbf·in Max. Termination Torque 12 lbf·in Max.
Operating Temperature -40 °F to +221 °F (-40 °C to +105 °C) Operating Temperature -40 °F to +250 °F (-40 °C to +125 °C)
Material Material
Contact Brass, Tin Plated Contact Copper Alloy
Screw #6-32, Combo Head, with SEMS Washer Screw Screw M3, Slotted
Insulator Body Polycarbonate, UL 94V-0, Black Insulator Body Polyamide PA, UL 94V-2, Gray
Electrical Electrical
Voltage Rating 300 Vac Voltage Rating 300 Vac
Current Rating 20 Amp Current Rating 20 Amp
Wire Range 12-24 AWG Wire Range 10-28 AWG

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Xpac Series 3 - Installation and Operation Manual - 9/22 20

1.8.5 Operational Summary

The CPU converts an incoming control
Double Acting Cylinder
signal into a target position. The current
position is determined through the Movement
feedback assembly mounted on the
actuator. The difference between the
target and current position is the error. If
the error exceeds the user set deadband
then the CPU will initiate corrective
action by starting the motor.
E2
A reversible hydraulic pump is driven
by the motor. The pump can pressurize
D2 A2
either side of a double acting cylinder FMV2
through one of two sides of the Flow C2 B2 Thermal
Matching Valves, FMV-1 and FMV-2. Each Expansion Gear Pump
Chamber
FMV side is comprised of a ported spool
B1 C1
with an integral pilot operated check A1
valve.

In the example in Figure 1.8.5-1; to move E1 D1

FMV 1
the cylinder piston to the left, the pump
turns in the direction to pressurize FMV-
2 through port A2. The spool in FMV-2 Figure 1.8.5-1 Hydraulic Schematic
becomes unbalanced by the pressure
differential and moves to the left, lifting its check valve, opening port D2 to port B2 and port A2 to port E2.

High pressure fluid flows through Port E2 to the right side chamber of the cylinder. Since the hydraulic circuit is closed, the same
amount of oil that flows into the right side of the piston must be extracted from the left side. This allows oil movement without an
active reservoir. This oil flows through the open check valve of FMV-2 and into pump suction.

By rotating the pump in the opposite direction, the FMVs operate in reverse
to move the cylinder piston to the right. When the pump stops, both check
valves close, and the hydraulic oil is locked within the cylinder. Motor
operation is not required to maintain position.

Each actuator has an internal hydraulic bypass circuit. This circuit creates a
direct connection from one side of the hydraulic cylinder to the other. It is
useful for relieving internal pressure in the actuator and allowing an external
load to move the actuator. The nut labeled bypass on the actuator face as
Gauge Gauge
shown in Figure 1.8.5-2 controls this circuit. Turning this bypass in all the way
puts the unit in its normal operation. Turning the bypass out 1 to 2 turns will CW Off CW Off
CCW On CCW On
open this bypass circuit.

Note: This bypass nut is only on units without internal solenoids.

Bypass

Each pressure gauge on the actuator has its own on/off isolation valve (Figure CW Off
1.8.5-2). This valve should remain off unless pressure is being read from the CCW On

gauge. This will protect the gauge from constant cycling, thus extending its
life. When closing this valve you will create an internal pressure trap in the
gauge; therefore, you should not expect to see 0 psi when off.

Figure 1.8.5-2 Bypass

1. General Information
 21 2. Delivery

2 Delivery

2.1 Receipt
REXA makes every effort to package products to avoid damage in shipping. Upon receipt inspect the crate and make note of any
physical damage. If severe damage is present, then consideration should be given to rejecting the shipment and contacting the
shipping company concerning in-transit damage claims.

2.2 Storage
If the actuator and control enclosure sub-assemblies are not immediately installed, provisions for storage must be made. The
equipment should not be removed from the original containers and should be protected from the elements. The ambient
environment must be:

• Clean—no airborne particles or contaminants.

• Non Corrosive—minute quantities of gases can concentrate in a confined area.
• Dry—relative humidity must be sufficiently low to prevent moisture condensation on chilled metal components.
• Temperature—recommended storage temperature is between 10 °F – 120 °F (–12 °C – 50 °C).

2.3 Unpacking
The REXA Xpac Actuator is shipped filled with oil and ready to be installed. It has been operated, tested and thoroughly inspected.
After removing the actuator from the packaging, inspect it for any signs of mechanical damage that may have occurred during
shipping. Immediately report any damage to the factory.

Compare the contents to the packing list included with every shipment. Immediately report any discrepancies to the factory.

2.3.1 Unpacking System, Lifting

If a piece of the system weighs between 40 – 79 lb (18 –36 kg), the manual must tell the installer that a two-man lift is required.

If a piece of the system weighs between 80 lb and 129 lb (36 kg – 59 kg), a three-man lift must be used.

Above 129 lb (59 kg), a machine assist must be used (forklift or crane)

2.4 Installation Requirements

2.4.1 Operational and Maintenance Clearances
Volts to Ground Condition 1
0–600 900 mm (3 ft)

Exposed live parts are on one side and no live or grounded parts are on the other side of the working space. Or, exposed live parts
on both sides are effectively guarded by wood or other suitable insulating materials. Insulated wire or insulated busbars operating
at not over 300 V to ground shall not be considered as live parts.

2.4.2 Hazards Due to Height

Use Safety Harness when working aloft above 1.8 m and consult Plant Safety Policy for safety consciousness and harness requirements.

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 22

3 Electrical Installation

Control Enclosure Overview

The electrical installtion block diagram (Figure 3) gives a general overview of the Control Enclosure and Actuator installation.

Note: Not all actuators will have all the options shown in Figure 3.

3.1 Control Enclosure Installation

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

It is necessary to verify the enclosure door is closed tightly and any openings added are sealed to comply with the
ratings given above.

Note: Reaffirm with unit’s tagging the Control Enclosure’s intended location.

Push Button and MAIN POWER INPUT

Transient
4x20 VFD Assy. 115 VAC, 1Ø, 50/60 Hz for B, C, ½ D
Door Mounted or
Motor Driver(s) Surpressor
230 VAC, 1Ø, 50/60 Hz for D/2D
Internal 230 VAC, 3Ø, 50/60Hz, for D,P9/D,P20/D,P40
PE
Motor Power
Digital I/O

Digital I/O

L Series Actuator
R Series Actuator
D Series Actuator
USER INPUT
Control Signal In
4-20mA Power Supply
Power Module and/or Motor Power Cable Power Module(s)
115 VAC IN or
230 VAC IN
+5/±15/+24 VDC
Optional
Output Failsafe
Solenoid
CPU Assembly
4-20mA Output / Internal or External +24 Feedback Cable: 4-20mA Loop, +15VDC Loop Supply Pressure
VDC Loop Supply
SPST SSR Limit Output (x2)
Transducer(s)
SPST SSR Alarm Output
SPST SSR Warning Output
SPST SSR Not-In-Auto Output Feedback Cable: 4-20mA Loop, +15VDC Loop Supply

Feedback Cable: 4-20mA Loop, +15VDC Loop Supply

Actuator
Feedback Board
DIGITAL I/O

Control Enclosure
Assembly Actuator
Feedback Board
Std. is 316 Stainless Steel NEMA 4x
USER I/O Contact In
24 - 120 VAC/VDC INPUT
120 VAC SSR OUTPUT Relay Out

Figure 3.1 Electrical Installation Block Diagram

3. Electrical Installation
 23 3. Electrical Installation

3.2 Main Power

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

Figure 3.2 Control Enclosure

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

Table 3.2 Power Requirements

Power Module Size Incoming Voltage Maximum Current Required Motor Power Requirement*
B 115 VAC ±10%, 50/60 Hz 4.0 amp 500 VA
C 115 VAC ±10%, 50/60 Hz 8.5 amp 1100 VA
½D 115 VAC ±10%, 50/60 Hz 20.0 amp 2400 VA
B 230 VAC ±10%, 1Ø, 50/60 Hz 2.0 amp 500 VA
C 230 VAC ±10%, 1Ø, 50/60 Hz 3.0 amp 1100 VA
½D 230 VAC ±10%, 1Ø, 50/60 Hz 10.0 amp 2400 VA
D 230 VAC ±10%, 1Ø, 50/60 Hz 10.0 amp 2400 VA
D,P9 230 VAC ±10%, 3Ø, 50/60 Hz 25.0 amp 9000 VA
D,P20 230 VAC ±10%, 3Ø, 50/60 Hz 30.0 amp 12000 VA
D,P40 230 VAC ±10%, 3Ø, 50/60 Hz 50.0 amp 21000 VA

* If another voltage is to be used, an External Step Up/Down Transformer of the proper size must be used.

Note: Dual module configurations, i.e. 2C, 2 1/2D and 2D, power consumption requirements are twice their single module.

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 24

3.2.1 Supply Disconnect Device

To comply with IEC 61010-1, Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use, a supply
disconnect device with the proper rating MUST be installed. The supply disconnecting device:

a. Shall disconnect (isolate) the Control Enclosure/Actuator from the supply when required.

b. Shall be included in the building installation.

c. Shall be in close proximity and within easy reach of the Control Enclosure.

d. Shall be marked as the disconnecting device for the equipment.

Refer to the Nameplate Rating of the Control Enclosure sub-assembly for proper sizing of the required disconnect device.

It is the responsibility of the installer of this equipment to provide a suitable disconnect for the Control Panel supplying
power to this equipment.

This disconnect must:

• Be suitable for the Voltage and Full Load Ampere Rating of all downstream equipment supplied by the Panel;

• The supply disconnecting device shall be one of the following types:

a. Switch disconnector with fuses, in accordance with IEC 60947-3, utilization category AC-23B or DC-23B.

b. As above, except one that has an auxiliary contact that in all cases causes switching devices to break the load circuit
before the opening of the main contacts of the disconnector.

c. A circuit breaker suitable as an isolation device per IEC 60947-2.

d. Any other switching device in accordance with an IEC product standard that also meets the isolation requirements of
IEC 60947-1 and is appropriate for on-load switching of the largest motor or other inductive loads.

• Be approved for use as a disconnect for the country in which this equipment is installed.

• Be provided with a Lock Out Tag Out capability in the Off (Down) position.

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

3.2.2 Grounding
Protective Earth Ground: A dedicated Protective Bonding Conductor (Protective Earth, PE) must be provided. The conductor must
be connected to the terminal labeled PE or . Protective bonding provides protection against electrical shock and should be
provided at both Control and Actuator.

3.2.3 Grounding Symbols

Protective Earthing

Safety Earth Ground

Noise Free (EMI) Ground

Frame/Chassis Ground

3. Electrical Installation
 25 3. Electrical Installation

3.2.4 Main Power Supply Wiring

It is the responsibility of the Installer of this equipment to supply suitable main power supply wiring. Consult the Manufacturer’s
Identification Nameplate on the Machine to determine Voltage and amperage requirements when determining the wiring size (mm2).

• The supply wiring must be approved for use in the country in which this equipment is installed or bear the <HAR> Mark.

• A separate bi-color ground wire that is green in color with a yellow stripe must be run in the hard-pipe conduit along with
the supply wiring.

• The conduit must be grounded in accordance with the National wiring rules of the country where installed.

• The fittings installed where the service wiring enters the body of the panel must not reduce the panel Ingress Protection rating.

3.2.5 Cordage
It is the responsibility of the Installer of this equipment to supply a suitable length of heavy duty supply cordage. It should meet
the following requirements:

• It must be approved for use in the country in which this equipment is installed or bear the <HAR> Mark.

• The maximum length of the cordage should not exceed the values established by the National Electric Code of the country
in which it is installed.

• The outer jacketing of the cordage should be rated for exposure to water, oil and other similar substances.

• The Voltage and Ampere rating of this equipment, as noted on the Manufacturer’s Identification Label, should be consulted
when selecting the proper size (mm2) of the cordage.

• A suitable industrial style attachment plug should be selected for connecting to the branch circuit. As an alternative, the
end that terminates at the building supply source may be permanently connected in accordance with local wiring rules.

• The supply cordage should be routed to the Control Cabinet in a manner that does not allow it to be stepped on, pinched,
subject to abrasion, excessive bending, become a trip hazard or subject to other abuse.

• Refer to REXA interconnect drawings for details of interconnect cable requirements.

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Xpac Series 3 - Installation and Operation Manual - 9/22 26

3.2.6 Fuse Identification / Replacement

Table 3.2.6-1 CSA/General Locations Fuse Replacement/Identification
System Description Standard Fuse (A) Alternate Configuration Fuse (A) Fuse Type
B Module, 115 VAC 5 15
B Module, 230 VAC 5 15
C Module, 115 VAC 10 20
C Module, 230 VAC 10 20
2B Module, 115 VAC 10 N/A
2B Module, 230 VAC 10 N/A
2C Module, 115 VAC 15 N/A
2C Module, 230 VAC 15 N/A
Type ‘CC’; 600 VAC, IR 200kA, 10mm x 38mm
1/2D Module, 115 VAC 20 30
1/2D Module, 230 VAC 10 20
D Module, 230 VAC 10 20
Dual 1/2D Module, 115 VAC 30 N/A
Dual 1/2D Module, 230 VAC 20 N/A
Dual D Module, 230 VAC 20 N/A
D, P9, 230 VAC 25 N/A
D, P20, 230 VAC 30 N/A
D, P40, 230 VAC 50 N/A Type ‘J’; 600 VAC, IR 200kA, 27mm x 60mm

Table 3.2.6-2 ATEX/IEC Locations Fuse Replacement/Identification

System Description Standard Fuse (A) Alternate Configuration Fuse (A) Fuse Type
B Module, 115 VAC 6 10
B Module, 230 VAC 4 10
C Module, 115 VAC 10 16
C Module, 230 VAC 6 12
Type ‘aM’; 500V, IR 120kA, 10mm x 38mm
2B Module, 115 VAC 10 N/A
2B Module, 230 VAC 10 N/A
2C Module, 115 VAC 16 N/A
2C Module, 230 VAC 12 N/A
Standard: Type ‘aM’; 500V, IR 120kA, 10mm x 38mm
1/2D Module, 115 VAC 20 32
Alternate: Type ‘aM’; 400V, IR 120kA, 10mm x 38mm
1/2D Module, 230 VAC 10 20
Type ‘aM’; 500V, IR 120kA, 10mm x 38mm
D Module, 230 VAC 10 20
Dual 1/2D Module, 115 VAC 32 N/A Type ‘aM’; 400V, IR 120kA, 10mm x 38mm
Dual 1/2D Module, 230 VAC 20 N/A
Type ‘aM’; 500 V, IR 120kA, 10mm x 38mm
Dual D Module, 230 VAC 20 N/A
D, P9, 230 VAC 25 N/A Type ‘aM’; 400V, IR 120kA, 10mm x 38mm
D, P40, 230 VAC 50 N/A Type ‘aM’; 690V, IR 120kA, 22mm x 58mm

3. Electrical Installation
 27 3. Electrical Installation

Table 3.2.6-3 Power Supply Identification

Power Supply Fuse Location Description Voltage (V) Amperage (A) SC I/R (A) Type Size
F1 Heater 250 2.0 35 S500 5 × 20mm
230 V Power Supply

F2 Trip / Fail Solenoid 250 2.0 35 S500 5 × 20mm

F3 Trip / Fail Solenoid 250 2.0 35 S500 5 × 20mm
F4 Heater 250 2.0 35 S500 5 × 20mm
F5 Position Transmitter 250 1/4 35 S506 5 × 20mm
F8 Line 250 1/4 35 5ST 5 × 20mm

F1 Trip / Fail Solenoid 250 2.0 35 S500 5 × 20mm

115 V Power

F2 Heater 250 3.15 35 S500 5 × 20mm

Supply

F3 Line 250 1/2 35 S506 5 × 20mm

F4 Position Transmitter 250 1/2 35 S506 5 × 20mm

3.3 Conduit and Conduit Fittings

• Conduit and Conduit fittings suitable for the environment must be used. Failure to do so may cause ingress of contaminants
or water into the enclosure.

• A removable gland plate is provided on the bottom of the Control Enclosure. The gland plate can be removed to machine
the appropriate conduit openings. Be sure to reattach the gland plate securely with its gasket in place.

• Seal all conduit threads with Locktite 567™ or equivalent to prevent ingress of moisture.

• Be sure fittings are tightened securely.

• Must maintain IP66 for steel, IP67 for stainless and fiberglass electronics enclosures, as well as actuator assembly.

• For applications requiring hazardous and explosion proof systems, conduit and conduit fittings must be properly installed
to NEC (National Electrical Code) wire standards to meet the area classifications:

CSA Class I Division 1, Groups C and D; -40C to 60C; T3

ATEX II 2G EX db [ia IIC] IIB T3, -40C≤Tamb≤60C

• Follow the National Electrical Code (NEC) and appropriate Local Codes for installation of Industrial equipment.

Refer to Appendix P for Interconnect Diagram.

Warning: The position transmitter used in the REXA CPU is extremely accurate and sensitive. Because of its high sensitivity, directly shorting
this circuit with an ammeter can cause damage to the circuit. The load resistance of the DCS needs to be present to protect this circuit from
a direct short. Without the load resistance (i.e., using an ammeter), premature failure of the Position Transmitter may occur. Refer to the
Troubleshooting and Repair Manual for proper testing procedure.

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Xpac Series 3 - Installation and Operation Manual - 9/22 28

4 Mechanical Installation

The Xpac can operate any device requiring force and stroke or torque and rotation. These include louvers, dampers, variable speed
drives, and valves. These instructions apply to any device that may be controlled by the Xpac.

4.1 Pre-Installation Checklist

Before installation of the actuator, check for the following:

• Ensure that the equipment was not damaged during shipping.

• Confirm that the electronic sub-assembly number and actuator serial number match.

• Verify that there is sufficient clearance for installation.

• Ensure that interconnect cables are present and are the proper length.

• Make certain that all the necessary equipment, tools and personnel are present for installation.

• Ensure all hydraulic tube fittings are tight.

4.2 R Series (Rotary)

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

4.2.1 Rotary Mounting (Fail in Place)

This operation requires the unit to be closed using the handwheel or manual hydraulic pump. Refer to Appendix M Manual Operators
for handwheel or manual hydraulic pump information. If the unit is not supplied with either, it must connect to the electronics and
manual operation used to drive it to the closed position. Refer to Manual Mode in Section 6.

a. With the actuator separated from its mounting, rotate the driven device to the closed position.

Note: Be aware that not all bolt patterns are square; refer to layout drawing for reference.

b. Place the mounting bracket on the driven device.

c. Hand tighten fasteners.

d. Install the shaft coupling if applicable. Confirm the correct position of the shaft key position on both actuator and driven device.

Note: Be sure to use anti-seize compound on mating surfaces.

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

Note: If a discrepancy exists between mating connections, check orientation of assembly components.

f. Check alignment of assembly. Ensure that the actuator face and mounting bracket are parallel, with no gaps.

g. Tighten fasteners in a star pattern.

4. Mechanical Installation
 29 4. Mechanical Installation

4.2.2 Rotary Mounting (Universal Spring Fail)

The universal rotary spring package is a bolt on addition to the REXA R Series Actuator. The unit may rotate in either a clockwise
or counterclockwise direction upon power loss. To complete this feature, a normally open solenoid valve is installed in the power
module and usually wired to the input power. Please refer to Product Memo 4, Spring Fail, for additional information.

If the unit has a REXA solenoid valve it will have the toggle lever shown below. Toggling this lever will override the function of the
solenoid. If the unit has no power and you need to use the Handwheel, Drill Drive or Manual Hydraulic Pump the lever must be in
the solenoid override position as shown in Figure 4.2.2.

CAUTION: Make sure the toggle lever is returned to its normal position when solenoid power is returned, or the
spring fail function will not operate properly.

Figure 4.2.2 Solenoid Override Position

The spring package will be pre-loaded (compressed) to a specified torque as indicated on the order. The pre-loaded torque is set at
an angle of 45° to the spring axis. Installation of the driven device within 5° of this position is acceptable.

Actuators are usually shipped in the fail position. Refer to Appendix M, Manual Operators, for information concerning the Handwheel
or Manual Hydraulic Pump.

CAUTION: REXA actuators, denoted by an E, R or U in the model number, contain a spring under tension.

a. With the actuator separated from its mounting, rotate the driven device to the fail position.

Note: Be aware that not all bolt patterns are square; refer to layout drawing for reference.

b. Place the mounting bracket on the driven device.

c. Hand tighten fasteners.

d. Install the shaft coupling if applicable. Confirm the correct position of the shaft key position on both actuator and
driven device.

Note: Be sure to use anti-seize compound on mating surfaces.

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

Note: If a discrepancy exists between mating connections, check orientation of assembly components.

f. Check alignment of assembly. Ensure that the actuator face and mounting bracket are parallel, with no gaps.

g. Tighten fasteners in a star pattern.

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Xpac Series 3 - Installation and Operation Manual - 9/22 30

4.2.3 Rotary Mounting Accumulator

Fail mode operation uses a piston type accumulator with nitrogen gas on one side of the piston and oil on the other. The accumulator
is sized to provide full rated output at end of stroke during fail mode.

The following operation requires the unit to be in the closed position; if it is not, use the handwheel or manual hydraulic pump.
Refer to Appendix M, Manual Operators, for information concerning the Handwheel or Manual Hydraulic Pump. If the unit is not
supplied with a handwheel or manual hydraulic pump, the unit must be connected to the electronics and manual operation used
to drive it to the closed position. Refer to Manual Mode in section 6.

a. With the actuator separated from its mounting, rotate the driven device to the closed position.

Note: Be aware that not all bolt patterns are square; refer to layout drawing for reference.

b. Place the mounting bracket on the driven device.

c. Hand tighten fasteners.

d. Install the shaft coupling if applicable. Confirm the correct position of the shaft key position on both actuator and
driven device.

Note: Be sure to use anti-seize compound on mating surfaces.

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

Note: If a discrepancy exists between mating connections, check orientation of assembly components.

f. Check alignment of assembly. Ensure that the actuator face and mounting bracket are parallel, with no gaps.

g. Tighten fasteners in a star pattern.

4.3 L Series (Linear)

REXA L Series Actuators utilize a sliding stem, piston-style cylinder. Mounting to the driven device is typically done with a bolted
yoke assembly. Stem connections will vary by application. Refer to Appendix B for information on Stem Connection & Seat Loading
Methods.

4.3.1 Linear Mounting (Fail in Place)

Actuators are usually shipped in the retracted position. Refer to Appendix M, Manual Operators, for information concerning the
Handwheel or Manual Hydraulic Pump. Refer to Appendix B, Stem Connections and Seat Loading Methods.

CAUTION: When mounting linear actuators, take care to avoid mechanical misalignment that would cause side-load
to the actuator output shaft. Be sure that the driven device is straight and true. Severe side-load will cause excessive
wear to both the actuator and driven device.

a. With the actuator separated from its mounting, rotate the driven device to the retracted position.

b. Retract the actuator stem to a position that will allow mounting the actuator without contacting the valve stem. If the
optional handwheel is not available, the unit must be connected to the electronics and manual operation used to drive
it to the closed position. Refer to Manual Mode in Section 6.

c. Place the actuator onto the driven device’s mating surface and loosely install the mounting hardware.

Note: Loose set up allows for float and self-alignment.

d. Extend the actuator stem until the coupling contacts the valve stem.

4. Mechanical Installation
 31 4. Mechanical Installation

e. Thread the driven device stem into the coupling for a distance of at least one and one half times the stem diameter and
use a lock nut against the coupling to prevent the stem from rotating out.

Note: There are wrench flats machined on the actuator stem for this purpose. No damage will occur if the actuator stem is rotated.

f. If the actuator is installed in a vertical position, manually stroke it to allow the stem connection to self-align.

g. Securely tighten the mounting connection. Visually inspect the stem for any noticeable indication of bending.

Support the actuator in a manner that prevents stem bending. Securely tighten the mating connection. Manually stroke the
actuator and carefully observe the stem for any evidence of lateral (side-to-side) misalignment.

h. For verification, once the mounting hardware is tight and the actuator is installed, decouple the actuator shaft. If any
movement of the actuator shaft can be seen during the process, loosen the mounting hardware, realign the actuator
and repeat steps f, g and h.

4.3.2 Linear Mounting (Spring Fail)

The spring fail option for linear actuators consists of a spring mounted underneath the hydraulic cylinder and a normally open
solenoid valve installed on top of the power module. The spring can be specified to extend or retract the stem upon power loss. It
is not field reversible. The solenoid valve is usually wired to the input power.

If the unit has a REXA solenoid valve it will have the toggle lever shown in Figure 4.3.2. Toggling this lever will override the function
of the solenoid. If the unit has no power and you need to use the hand wheel, drill drive or manual hydraulic pump the lever must
be in the solenoid override position as shown in Figure 4.3.2. Note that the REXA solenoid valve option is only available for systems
with B, C, 1/2D, and D power modules rated for hazardous but non-explosion proof environments.

CAUTION: Make sure the toggle lever is returned to its normal position when solenoid power is returned, or the
spring fail function will not operate properly.

Figure 4.3.2 Solenoid Override Position

CAUTION: REXA actuators, denoted by an E, R or U in the model number, contain a spring under tension.

4.3.3 Linear Mounting Accumulator

Fail mode operation uses a piston type accumulator with nitrogen gas on one side of the piston and oil on the other. The accumulator
is sized to provide full rated output at end of stroke during fail mode.

Actuators are usually shipped in the retracted position. Refer to Appendix M, Manual Operators, for information concerning the
Handwheel or Manual Hydraulic Pump. Refer to Appendix B, Stem Connection and Seat Loading Methods.

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Xpac Series 3 - Installation and Operation Manual - 9/22 32

CAUTION: When mounting linear actuators, take care to avoid mechanical misalignment that would cause side-load
to the actuator output shaft. Be sure that the driven device is straight and true. Severe side-load will cause excessive
wear to both the actuator and driven device.

a. With the actuator separated from its mounting, rotate the driven device to the retracted position.

b. Retract the actuator stem to a position that will allow mounting the actuator without contacting the valve stem. If the
optional handwheel is not available, the unit must be connected to the electronics and manual operation used to drive
it to the closed position. Refer to Manual Mode in section 6.

c. Place the actuator onto the driven device’s mating surface and loosely install the mounting hardware.

Note: Loose set up allows for float and self-alignment.

d. Extend the actuator stem until the coupling contacts the valve stem.

e. Thread the driven device stem into the coupling for a distance of at least one and one half times the stem diameter and
use a lock nut against the coupling to prevent the stem from rotating out.

Note: There are wrench flats machined on the actuator stem for this purpose. No damage will occur if the actuator stem is rotated.

f. If the actuator is installed in a vertical position, manually stroke it to allow the stem connection to self-align.

g. Securely tighten the mounting connection. Visually inspect the stem for any noticeable indication of bending.

For all other orientations, support the actuator in a manner that prevents any noticeable indication of stem bending. Securely tighten the
mating connection. Manually stroke the actuator and carefully observe the stem for any evidence of lateral (side to side) misalignment.

h. For verification, once the mounting hardware is tight and the actuator is installed, de couple the actuator shaft. If any
movement of the actuator shaft can be seen during the process, loosen the mounting hardware, realign the actuator
and repeat steps f, g and h.

4.4 D Series (Drive)

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

4.4.1 Drive Mounting

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

Table 4.4.1- Drive Base Bolting

RECOMMENDED Bolt Torque
Model Hole Diameter Min. Bolt Diameter
Minimum Maximum
D2 500/5 000 .56 ” ½” 20 lb·ft 30 lb·ft
D10 000/20 000 .81” ¾” 200 lb·ft 250 lb·ft
D50 000/100 000 1.00” 1” 650 lb·ft 700 lb·ft

Note: Bolting to be SAE Grade 8.

4. Mechanical Installation
 33 4. Mechanical Installation

4.4.2 Drive Arm

Connection to the driven device (linkage) is by means of the drive arm. Standard arms are based upon actuator size. Each arm
includes multiple connection points. See Figure 4.4.2-1. Custom arms are available upon request.

The connecting link and other linkage should be selected to withstand the maximum load imposed by the drive. This will vary
depending upon the effective length of the arm. The following equation should be used to determine the minimum safe working
load of the connecting linkage:

For most installations, the optimum alignment of the drive arm and the driven (damper) arm is when they are parallel to each other
and perpendicular to the connecting linkage at mid-rotation. Refer to Figure 4.4.2-2. This is accomplished by a combination of
linkage length and drive arm adjustments. A slotted spline connection between the drive arm and shaft provides multiple mating
angles (5°-10° intervals).

Figure 4.4.2-1 Drive Arm Assembly Reference Drawing

Rated Drive Torque

Load x5
Effective Lever

Figure 4.4.2-2 Drive Arm Alignment

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Xpac Series 3 - Installation and Operation Manual - 9/22 34

5 Start-Up Considerations

5.1 Start-Up Checklist

At this time the actuator, electronics sub-assembly and driven device should be installed. Before applying power to the unit and
calibrating the actuator the following items should be considered:

5.1.1 Inspection of Electronic Sub-Assembly Installation

Check the following:

⃞ Inspect incoming voltage connection.

⃞ Test for correct incoming voltage

⃞ Control signal connections are secure.

⃞ Outgoing signals are connected properly.

⃞ Interconnection cable wiring is correct at electronic sub-assembly, actuator junction boxes and terminal blocks.

⃞ Feedback cables are connected and shielded properly at actuator/electronics.

⃞ All ground wires are secured.

⃞ All electrical connections are tightened properly.

⃞ Conduit connections are secure and watertight with thread sealant.

⃞ Electronics are free of tools and debris.

⃞ Proper personnel has been notified for lock out/ tag out procedures.

5.1.2 Inspection of Mechanical Actuator Installation

Check the following:

⃞ Oil level is correct.

⃞ Motor and feedback wires are connected properly and securely.

⃞ Actuator mounting fasteners are tight.

⃞ Coupling/split clamp installed properly.

⃞ All conduit connections are secure and watertight with thread sealant.

⃞ All tools and equipment are clear of operating area.

⃞ Safety related covers and labels are installed and clearly marked.

⃞ Proper personnel has been notified for lock-out/tag-out procedures.

5. Start-Up Considerations
 35 5. Start-Up Considerations

5.2 Alignment
Any noticeable bending of the actuator stem or driven device should be immediately corrected. Not only will operation be impaired,
but damage to the actuator seals and bushings or driven device may occur. When mounting the actuator to the driven device the
actuator shafts and couplings must align properly.

5.2.1 Lateral Alignment

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

5.2.2 Longitudinal Alignment

LINEAR
Failure to reach full stroke is caused by a mechanical limitation within the actuator or driven device. Incorrect yoke leg lengths or
thread engagement in the stem coupling may reduce the travel. In most cases, the required adjustment is small and can simply be
made by changing the length of thread engagement of the stem coupling. Further adjustment can only be made by changing the
length of the yoke legs.

If the actuator is installed in a vertical position, manually stroke it to allow the stem connection to self-align. Securely tighten the
mounting connection. Visually inspect the stem for any noticeable indication of bending.

For all other orientations, support the actuator in a manner so that there is no noticeable indication of stem bending. Securely tighten the
mating connection. Manually stroke the actuator and carefully observe the stem for any evidence of lateral (side to side) misalignment.

ROTARY (<90° Rotation)

Failure to reach the full 90° rotation is usually not binding, but rather an installation problem. With the actuator separated from the
driven device, rotate the driven device to the closed position. Move the actuator in the same direction until the end of rotary piston
travel is reached. The connections between the driven device and the actuator should be within 2-4 degrees. If a large discrepancy
exists between the mating connections, the adapter may be incorrect.

DRIVE
Drive units can create an extraordinary amount of force. Any misalignment of the drive/driven arms, or incorrect linkage
arrangements, can cause damage to the actuator or the driven device. All mechanical connections and stroke limits should be set
carefully and inspected.

5.3 Initial Calibration

Refer to Section 5.4, Rotary and Drive Spring Stops, and Section 5.5, Cylinder End Stops, prior to calibrating rotary or drive units with spring
or accumulator fail option.

• Apply AC Power.
Line 2 will display the CALIBRATE menu header.

• If not already in CALIBRATE, simultaneously press AUTO and MANUAL for 5 seconds.

• Scroll down to Position Lo with the arrow.

• Press the ENTER ( ) key. = will begin to flash. Value will change to current actuator position.

• Move the actuator to the Position that corresponds to 4.0 mA.

Refer to Appendix B, Stem Connection & Seat Loading Methods.

• Press the ENTER ( ) key to lock in that value.

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Xpac Series 3 - Installation and Operation Manual - 9/22 36

CAUTION: The end point should not be set against a mechanical stop without a spring coupling or damage will occur.
Note: If the actuator is stroked beyond the factory set cylinder limit, the display will show CylEnd while the down key is held. If the enter
key is pressed, the display will show TooLow. Position Lo will need to be calibrated higher until this warning goes away.
• Scroll down to Position Hi with the arrow.
• Press the ENTER ( ) key to lock in that value.
• Press the ENTER ( ) key. = will begin to flash. Value will change to current actuator position.
• Move the actuator to the Position that corresponds to 20.0 mA.
• Press the ENTER ( ) key to lock in that value.
CAUTION: The end point should not be set against a mechanical stop without a spring coupling or damage will occur.
Note: If the actuator is stroked beyond the factory set cylinder limit, the display will show CylEnd while the up key is held. If the
enter key is pressed, the display will show TooHi. Position Hi will need to be calibrated lower until this warning goes away.
• Scroll down to Signal Lo with the  arrow.
• Press the ENTER ( ) key. = will begin to flash.
• Apply the actual 4.0 mA Control Signal from the DCS. The value in the display will change; showing what is being read from the DCS.
• Press the ENTER ( ) key to lock in that value.
• Scroll down to Signal Hi with the arrow.
• Press the ENTER ( ) key. = will begin to flash.
• Apply the actual 20.0 mA Control Signal from the DCS. The value in the display will change; showing what is being read
from the DCS.
• Press the ENTER ( ) key to lock in that value.
• Scroll down to TIME with the  arrow.
• Press the ENTER ( ) key. = will begin to flash. Change current hours, minutes, and seconds using  or  arrow. Press the
ENTER ( ) key to advance between hours, minutes, and seconds.
• Press the ENTER ( ) key to lock in each value.
• Scroll down to DATE Press the  arrow.
• Press the ENTER ( ) key. = will begin to flash. Change current year, month, and day using  or  arrow. Press the ENTER
( ) key toadvance between year, month, and day.
• Press the ENTER ( ) key to lock in each value.
The Actuator has now been calibrated. It is recommended at this point that all Current Status be reset
to 0. Refer to Current Status menu section for procedure.
To enter the Auto mode:
• Simultaneously press Auto ( ) and ENTER ( ).
Line 1 of the display will change to Auto followed by the Current Status.
Line 2 will be blank.
• When the keys are released
Line 2 will display the current Position.

5. Start-Up Considerations
 37 5. Start-Up Considerations

5.4 Rotary and Drive Spring Stops

Spring stops provide the actuator the means to prevent over-travel during a fail safe condition. If the driven device does not limit
over-rotation or over-travel, spring stops can be utilized for this purpose by turning the spring stop adjustment screw in or out to
modify the actuator’s final fail position.

To install a Spring Fail unit, position the spring lever to the 45° location by extending the spring stop as shown in Figure 5.4. Rotate the
driven device to the required failure position. Adjust the spring stop to allow mating of the shafts and alignment of the mounting bolts.

Once mounted, the spring stops should be adjusted to a position that transfers torque onto the driven device at the fail position.

Figure 5.4 Universal Spring Alignment

5.5 Cylinder End Stops

Cylinder end stops provide the actuator the means to prevent over-travel during a fail safe condition. If the driven device does not
limit over-rotation or over-travel, cylinder end stops can be utilized for this purpose. These stroke adjusters can reduce cylinder
rotation 0–5 degrees.

Figure 5.5 Stroke Adjustment

CAUTION: Ensure that there is no hydraulic pressure in the system prior to cracking any hydraulic lines. All pressure
gauges should read 0 psi.

Note: Each actuator is tested and shipped from the factory with the thread seal and jam nut lightly torqued—enough to seal during
factory acceptance testing. This procedure assures that the sealing rubber is undamaged and will properly seal once the stroke adjustor is
fully adjusted in the field by the end user, and the threaded elements are firmly tightened to full torque.

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Xpac Series 3 - Installation and Operation Manual - 9/22 38

5.5.1 End Stop Adjustment

Counter Clockwise
Adjuster Clockwise Adjuster

Figure 5.5.1-1 Cylinder End Stops

WARNING: The Calibrated end points PL and PH must not be set with the actuator against the cylinder end stop.

1. Position the actuator in the desired final fail position slightly beyond the calibrated end stop. This can be done when
calibrating PL and PH.

Note: Failure to follow this step will lead to a potential situation where the electronics may try to drive the actuator beyond its
physical limit, and a stall condition will result.

2. Turn off the power breaker in the electronics.

3. Locate the correct stroke adjuster (refer to Figure 5.5.1-1).

4. Locate the hydraulic fitting (1) connected directly to the stroke adjuster cylinder cap as shown in Figure 5.5. Loosen this
fitting to allow oil to escape during this adjustment process.

5. Loosen the jam nut (Figure 5.5.1-2) by turning counterclockwise. Back off this jam nut 4 to 5 turns and move the countersunk
washer away from the thread seal and against the repositioned jam nut.

6. Using light oil and a small brush or squirt can, generously lubricate the thread seal rubber and the threads of the adjustment screw.

7. Carefully pry the thread seal washer away from the end cap and then pull and twist it back and forth to carefully slide it
along the adjustment screw threads to gain adjustment clearance.

8. The actuator stroke adjustment can now be made using the threaded adjustment rod. This rod has a hollow hex in the end
to allow easy adjustment.

WARNING: As the stroke adjusters are turned in, fluid will be displaced and need to leak out of the system. Failure to exhaust
fluid will damage internal components of the actuator.

9. The actuator is shipped from the factory with this adjustment rod threaded fully out to the end of travel to give the full
rotation of the actuator. The adjustment screw can only be rotated clockwise (inward) from this shipped position.

Caution: A mechanical lock at the end of the threads restricts inadvertent disassembly outward. Rotating the adjustment screw
counterclockwise (outward) from this end position may cause damage to the hardware.

10. Use an allen wrench drive inserted into the hollow hex adjustment screw end to adjust the stroke adjustor. Rotate clockwise
to decrease the stroke of the actuator. Each stroke adjustor provides a minimum of 5 degrees of actuator rotation adjustment.

11. The number of adjustment screw rotations needed to achieve the 5 degree rotational adjustment of the actuator depends
on the size (model) of the actuator and the pitch of the adjustment thread on the adjustment screw. The Table 5.5.1 shows
this relationship.

5. Start-Up Considerations
 39 5. Start-Up Considerations

Figure 5.5.1-2 End Stop Detail

12. After final positioning of the adjustment screw to achieve the desired actuator rotation, readjust the position of the thread
seal along the adjustment screw threads to contact the end cap. Caution: use generous lubrication during this step to
assure no damage to the rubber seal by the threads.

13. Reposition the countersunk washer and the jam nut and torque the jam nut to the requirements of the Table 5.5.1.

14. Tighten the hydraulic fitting that was loosened in step 4.

Table 5.5.1 Stroke Adjustor

Model R2,500/R5,000 R10,000/R20,000 R50,000/R100,000 R200,000/R400,000
One Turn Adjustment (degrees) 3.3 2.0 2.0 1.2
Jam Nut Final Torque (lb·ft) 50 150 300 375

5.5.2 R200 000/R400 000 End Stroke Adjustments

R200 000/R400 000 actuators do not use an external thread seal arrangement. The seal is contained internally while the jam nut and
adjustment screw drive is located externally. Refer to Figure 5.5.2. An external drive square is provided on the adjustment screw
end and can be driven by using a standard wrench. No special lubrication of the threads is needed during adjustment.

The unit is shipped from the factory with the stroke adjuster positioned at the full outward position as described above. Adjustment
is made by disconnecting the hydraulic line to vent out any displaced fluid, loosening the jam nut several turns counter clockwise
and then using the square drive to position the adjuster to provide the desired actuator stop position. The total adjustment range
is 5 degrees minimum. Table 5.5.1 shows the adjustment achieved from one turn of the adjuster.

The jam nut is repositioned after adjustment is complete and torqued to the final tightness value specified.
Jam Nut

Drive Square

Adjustment Screw
Figure 5.5.2 R200 000/R400 000 Stroke Adjuster

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Xpac Series 3 - Installation and Operation Manual - 9/22 40

6 Modes of Operation & Control Parameters

The user interface is a four-line display with a five-button keypad. The display dims after five minutes without keypad usage. If an additional
five minutes pass without keypad usage, the display turns off completely. Pressing any of the five keys will wake up the display.

Figure 6.0.1 Display Label on Inside of Flip Cover

The REXA electronics has three different operating modes:

• SETUP – Calibration Mode

• AUTO – Remote Mode

• MANUAL – Local Mode

Enter each operating mode as shown below:

Figure 6.0.2 Modes of Operation

6. Modes of Operation & Control Parameters

 41

CURRENT HISTORIC
CALIBRATE CONTROL SPEED INPUTS DRIVES OUTPUTS
STATS STATS

NA if Signal
Type = 1 Cont

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

6. Modes of Operation & Control Parameters

X3 Control
Parameters Menu
NOTE: The Xpac Series 3 controller detects any auxiliary components which may be included with the system. If a
component is not part of the REXA system, then the associated control parameter will be absent from the menu.

 If the REXA does not have a Booster Pump assembly then the “Boost Offpt” parameter will not be visible.

Figure 6.0.3 Control Parameters Menu

Xpac Series 3 - Installation and Operation Manual - 9/22 42

6.1 Setup Mode

Setup mode is used to set the control and calibration parameters of the actuator. Most control parameters are factory set and
provide excellent actuator performance. Some applications may require fine tuning.
The eight main menus and accompanying control parameters are covered in the following sections. Refer to figure 6.0.2 to access
SETUP mode and change the parameters.
SETUP mode can be password protected. The default password value is 0000. This indicates that no password is set. If any other
value is set, the user will be prompted to enter the password to access the SETUP mode.
6.1.1 Menu Navigation
To enter SETUP mode, simultaneously press and hold the AUTO and MANUAL keys for 5 seconds.
Note: While in SETUP mode the actuator will not follow a control signal.
The menu tree of the control parameters is shown in figure 6.1.1
Pressing ENTER will scroll left to right from CALIBRATE through HISTORIC STATS and then repeat in a circular path.
Pressing the UP or DOWN arrow will scroll up and down each menu column.
6.1.2 Changing a Parameter
To access and change a parameter value, the parameter must be visible on the display (i.e. Position Lo). Pressing the ENTER button will cause
the equal sign to flash. This symbolizes that the system is ready for the user to input a change in value. Pressing the UP or DOWN arrows will
change the parameter value. To enter and accept the newly selected value, press the ENTER button. The equal sign will stop flashing.
6.1.3 CALIBRATE Menu
The CALIBRATE menu consists of the following parameters:
Position Lo defines the actuator position corresponding to the Signal Lo setting. If the Signal Type is set to Contact Input, Position
Lo defines the actuator position corresponding to the Closed Input.
Position Hi defines the actuator position corresponding to the Signal Hi setting. If the Signal Type is set to Contact Input, Position Hi
defines the actuator position corresponding to Open Input.
Note: The actuator will move when changing Position Lo and Position Hi. The total span between each parameter must be greater than
10%.
Signal Lo is the analog signal input at 4 mA that corresponds to Position Lo.
Signal Hi is the analog input signal at 20 mA that corresponds to Position Hi.
Range: 0.0 to 25.0 mA
Note: Signal Lo and Signal Hi are only visible if Signal Type is set to Analog. These parameters cannot be set by pressing the arrows. An
active 4-20 mA must be applied. The actual signal in milliamps will display.
Note: Unknwn will appear if a control signal failure occurs while calibrating. Error appears briefly if an unacceptable value is entered. The
unacceptable value is rejected, and previous value is retained. Input signal must be greater than 2.5 mA if Failsafe does not equal Off. If
Failsafe does equal off, the span from Signal Lo to Signal Hi must be greater than 3.8 mA. Refer to the Inputs menu for Failsafe information.
Time: HH/MM/SS sets local time
Date: MM/DD/YY sets local date
New Battery is a prompt to inform the user that the lithium ion clock battery, used to maintain time and date, has expired. Changing
the parameter to Yes will reset the battery life timer and clear the display warning.

6. Modes of Operation & Control Parameters

 43 6. Modes of Operation & Control Parameters

6.1.4 Control Menu

The CONTROL menu consists of the following parameters:

Deadband sets the maximum deviation allowed between the input signal and actuator position before a corrective movement is made.

Range: 0.05 to 5.00% percent of calibrated stroke/rotation

Deadband should be set to a value appropriate for the process being controlled. Ensure that the actuator is reacting to actual signal
changes as required and not just reacting to noise in the control signal itself.

Gain determines how motor speed is adjusted as the actuator approaches the target position. The higher the Gain setting, the
closer the actuator will get to the target position before decelerating. With a lower Gain setting, the actuator will begin decelerating
further away from the target position. This parameter is factory set to an ideal value for the actuator model configuration. It may be
changed if the application warrants it.

Range: 1 to 999

Figure 6.1.4 Gain

Min Mod (minimum modulation) defines a position value in the stroke/rotation below which the actuator will not modulate. Min
Mod sets the upper limit of a non-modulating span with respect to Position Lo. The actuator will move to Position Lo if any control
signal input falls within this span. This parameter may be used to minimize valve seat wear.

Note: If set, this parameter will function in AUTO and MANUAL mode. It is not visible in the menu if Signal Type is set to 1 Cont. or 2 Cont.

Range: Off or 0.1 to 99.9% percent of calibrated stroke/rotation

Bumpless (Bumpless Transfer) is a safeguard to prevent unwanted actuator movement when returning from MANUAL or SETUP mode
into AUTO mode. With the Bumpless parameter turned on, the actuator will wait for operator intervention before following the control
signal if the actuator position was moved manually or the control signal changed. To clear Bumpless, the operator must move the
actuator to within 5% of the new control signal or change the control signal to be within 5% the new actuator position. The adjustment
must be made within the set Deadband for the actuator to return to following the control signal.

This parameter only appears in the menu if the Signal Type is set to Analog or 1 Contact. See INPUTS and DRIVES menu.

Sol. Seat (Solenoid Seating) uses software to allow the stored energy of the fail-safe spring or accumulator (if equipped) to seat the
valve. This feature is only available on fail-safe actuators where the fail-safe direction is the same as the valve seating direction. In
such applications, this feature eliminates the need for an elastic coupling or a seat load cylinder.

Note: Solenoid Seat is not visible in the menu if seat load cylinder is configured.

Cal. Stroke (Calibrated Stroke) is used when configuring the Sol. Seat function. Calibrated Stroke defines the valve/driven device
stroke so the system can determine when to open the fail-safe solenoid and allow the spring of accumulator to seat the valve.

Range: 0.3 in to 99.9 in

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6.1.5 Speed Menu

The SPEED menu consists of the following parameters:

Max Hi Spd (Maximum High Speed) defines the maximum motor speed when operating in AUTO mode.

Range: 5 to 125% percent of maximum specified motor speed

2-Speed defines use of option two speed operation.

Select: Off, Up/Dn, Bkpt.

Default = Off

When 2-Speed is off, Maximum High Speed defines the maximum motor speed when in AUTO mode.

When 2-Speed is set to Bkpt, Max Lo Spd and Speed Bkpt are added to the menu.

Max Lo Spd (Maximum Low Speed) defines the maximum speed between Position Lo and the Spd Bkpt.

Range: 5 to 125% percent of maximum specified motor speed. Cannot be greater than Max Hi Spd.

Spd Bkpt (Speed Breakpoint) defines a break point to determine when to use Max Lo Spd or Max Hi Spd.

Range: 0.1 to 99.9% percent of calibrated stroke/rotation.

When 2-Speed = Up/Dn, MaxHi Spd is changed to Max Up Spd and Max Dn Spd is introduced to the menu. and defines maximum
motor speed as the actuator moves toward Position Hi.

Max Up Spd (Maximum Up Speed defines the maximum motor speed when moving toward Position Hi.

Range: 5 to 125% percent of maximum specified motor speed

Max Dn Spd (Maximum Down Speed defines the maximum motor speed when moving toward Position Lo.

Range: 5 to 125% percent of maximum specified motor speed

Max Man Spd (Maximum Manual Speed) defines the maximum motor speed when operating in SETUP mode.

6.1.6 INPUTS Menu

The INPUTS menu consists of the following parameters:

Signal Type defines the control signal the actuator will respond to in AUTO mode.

Select: Analog, 1 Cont, 2 Cont

Note: 1 Cont and 2 Cont are only included in the INPUTS menu if a contact board is installed

When Signal Type = Analog, the main control signal is the 4-20 mA analog input. This selection provides the full modulating
capability of the actuator.

When Signal Type = 1 Cont (one contact), two position on/closed operation—open/closed is selected. The applied signal defines
actuator position. If the Open input is active (powered), the actuator goes to Position Hi. If the Open input is not active (un-
powered), the actuator goes to Position Lo.

When Signal Type = 2 Cont (two contacts), manual modulation operation is selected. The main input signals are the contacts Open and
Close of the contact input board. If both inputs are active or inactive, the actuator remains in position. If only the Open input is active,

6. Modes of Operation & Control Parameters

 45 6. Modes of Operation & Control Parameters

the actuator moves toward Position Hi. If only the Close input is active, the actuator moves toward Position Lo.

Note: The actuator will continue to move in desired direction as long as a signal is present or until the target position is reached.

Failsafe defines the position the actuator moved to, via the motor, if the analog control signal falls below 2.5 mA. Only if Signal Type
– Analog.

Select:

Inplac: The actuator remains in current position.

Off: Used for zero based control signal, i.e, 0-20 mA

0-100%: Actuator goes to set position value.

Note: Failsafe function only affects AUTO mode operation.

Trip defines the active state of the trip signal input on the interconnect board. This input is used to override the control signal input
to cause actuator movement via the spring or accumulator. This fail-safe mechanism is factory configured to either end of stroke
or rotation. It is not field reversible.

When Trip = Off, trip function is not used

When Trip = Unpwrd, the trip input is to remove power

When Trip = Pwrd, the trip input is to present power

Power On parameter defines the mode the electronics will be in when main power is applied.

When Power On = Last, on power up or reset, the actuator will return to its previous operating mode (AUTO, MANUAL or SETUP).

When Power On = Local, on power up or reset, if the previous mode was AUTO, the actuator will enter MANUAL (Local) mode.

6.1.7 Drives Menu

The DRIVES menu consists of the following parameters:

Boost Offpt is the deviation between current position and control signal for the booster pump to turn off or on. It can be set
between 0.1% to 75% of calibrated span

Surge Bkpt {Surge Breakpoint} defines minimum deviation (in percent of calibrated span) between current position and the new
target position where a surge solenoid will operate. When the deviation exceeds the set value, the surge relay output is activated
and kept active until the current position matches the current control signal.

Surge Offpt {Surge Offpoint} defines the distance away from the new target position in which the surge solenoid is reenergized during
a surge event – effectively stopping the actuator movement. On systems with high speed trips this allows the REXA electronics to
change states of the solenoid to anticipate hitting the new target position and eliminate overshoot during a surge event.

Surge Offpt has a settable range of 0.1% to 5%.

If an actuator is equipped with an online-recharge accumulator or a spring fail-safe, the following five parameters are in the menu:

Surge Dir {Surge Direction} is displayed whenever Surge Bkpt is set to any value other than off. Surge Direction is settable to either to PL
(Position Low), or PH (Position High) which specifies the direction of action. PLPH is used for bi-directional accumulator surge control.

Rechrg Pres {Recharge Pressure} adjusts the pressure level at which an accumulator recharge cycle will end. Factory set in # (psi),
from Warn Pres + 200 up to Warn Pres + 3000 psi.

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Warn Pres {Warning Pressure} adjusts the pressure at which an accumulator low pressure warning is issued. Factory set from 1000
psi up to 2800 psi.

Note: The warning relay deactivates, and the status display will indicate Pres Low when the accumulator pressure drops below the value
set in Warn Pres.

Rechrg Time {Recharge Time} adjusts the maximum time allowed for a recharge cycle to complete. A recharge cycle ends when either the
Rechrg Pres setting is reached or the Rechrg Time expires. In either case, the actuator resumes tracking the control signal.

Power Fail defines what the accumulator will do on loss of power.

The parameter can be set to:

Accum- Unit will fail on loss of power

Inplace- Unit will not fail on loss of power, only trip input.

Accum Dir (Accumulator Direction) defines the direction the accumulator will move the actuator a power loss of trip event. This
parameter is factory. Its only purpose is to inform the REXA electronics as to which direction to operate the motor during a recharge
cycle after a trip. Accumulator fail-safe direction is not field reversible.

Accum Pres (Accumulator Pressure): This parameter cannot be set. It is the “live” pressure reading from the accumulator pressure
transducer.

Units: # (psi)

Range: 0 to 3000 PSI

Unknwn if “pressure bad” error

If an actuator is configured with an online-recharge accumulator or a spring fail-safe, the following parameters are in the menu:

PST defines an actuator use of partial stroke testing.

The parameter can be set to:

Off, CntPwr, CntUnp, Signal, Auto, ConPAu, CUnpAu

PST Target is added to the drives menu if PST is set to anything other than ‘Off’. Options are position from 95.0% to 50.1%, incremented
by .1%. Cannot be set less than PST Off Point.

PST Offpt is added to the drives menu if PST is set to anything other than ‘off”. Options are less “Off” or 95.1% to 50.2%. Value must be
higher than “PST Target”. PST Time is added to the drives menu if PST is set to anything other than “off”. Options 1 to 150 seconds

PST Time is added to the drives menu if PST is set to anything other than “off.” Options 1 - 150 seconds.

PST Inc {PST Increment} is added to the drives menu if PST is set to anything other than “off”. Options are “off” 0.1% to 1%.

PST Max Target is added to the drive’s menu if PST Inc is on. PST Max Target = 50.0 to 90.0% settable range, not greater than PST
Target.

PST Signal Deviation is the signal deviation from 100% to a new PST target position. This allows the analog control line to control the
actuator and avoids running a second PST command cable. Control signal deviation is used to initiate a PST cycle.

PST Auto Sch is only viewable if the auto schedule has to be turn on. Settable from 24 to 999 hours… PST will run automatically on
schedule from every 24hr. to 999hr

6. Modes of Operation & Control Parameters

 47 6. Modes of Operation & Control Parameters

Delta Warn is active when pressure exceeds setting value. When it is active Warn Relay is active, the actuator will still modulate
normally.

Units: # (psi)

Range: 500 to 2300 PSI

Delta Alarm is active when the pressure exceeds setting value. When it is active Alarm Relay is active, motor(s) are stopped, the
actuator can only move in the direction that relieves the alarm pressure.

Units: # (psi)

Range: 600 to 2400

Rdnt CPU defines if the REXA system is equipped with redundant CPU’s. Redundant CPU configured, BACKUP CPU modulates with
5% DEADBAND, MAIN CPU controls all moves < 5% deviation. When Main CPU in Alarm, BACKUP CPU will take role of MAIN CPU and
reduces Deadband to parameter setting in CONTROL Menu.

When redundant is selected in the menu a new parameter is available in the Calibration menu called “Linearize”

Linearize range can be set between -5% to 5% in .1% increments.

Calibration process:

1. Calibrate Position Low and Position High for both electronics

2. Move the actuator to 50% and record the delta between the position read outs on the two electronic displays

3. Go to calibrate menu in the redundant electronics and enter the delta recorded into the linearize parameter.

The redundant electronics will drop the decimal place on the position/feedback display when it’s acting as a redundant system.
When the redundant actuator changes to the primary the decimal digit will return to the display.

6.1.8 Outputs Menu

Relay #1 defines the point in % of calibrated stroke at which relay output 1 is active. The relay will be active when the actuator
position is = or < the value set in Relay #1

Relay #2 defines the point in % of calibrated stroke at which relay output 2 is active. The relay will be active when the actuator
position is = or > the value set in Relay #2

Display = Dir/Rev allows the position display to be reverse acting with position open and direct acting with position closed (i.e.
100%=closed instead of 100%=open).

Pos Xmitter {Position Transmitter} defines the action of the position transmitter output as being direct acting, Dir or reverse acting,
Rev.

When set to direct acting, a 4 mA output corresponds to Position Lo.

When set to reverse acting, a 4 mA output corresponds to Position Hi.

Xmitter Low (Transmitter Low) is the parameter to calibrate the output of the 4-20 mA Position Transmitter.

To calibrate the 4mA Zero, Set a digital multi-meter, DMM, to read milliamps (mA) DC. Connect the DMM to the Position Transmitter
Output. Connect the Red lead of the DMM to the LOOP OUT terminal. Connect the black lead of the DMM to LOOP INT RTN terminal.
Press Enter to access this setting. The Value displayed on the REXA display corresponds to Digital bits. Each increment or decrement of 4
bits and will increment or decrement the current output by one micro-amp (1 µA). The acceptable range for Xmitter Lo is 3.9 to 4.1 mA.

Note: The Position Transmitter will output the mA signal that corresponds to the actuators current position until the Enter button is pressed
and the “=” sign is flashing. When the “=” sign is flashing, the output will change to the “Zero” or Lo Calibration value.

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Xmitter Hi (Transmitter Hi) is the parameter to calibrate the Output span of the 4-20 mA Position Transmitter.

To calibrate the 20 mA Span, Set a digital multi-meter, DMM, to read milliamps (mA) DC. Connect the DMM to the Position Transmitter
Output. Connect the Red lead of the DMM to the LOOP OUT terminal. Connect the black lead of the DMM to LOOP INT RTN terminal.
Press Enter to access this setting. The Value displayed on the REXA display corresponds to Digital bits. Each increment or decrement
is steps of 4 bits and will increment or decrement the current output by one micro-amp (1 mA).

Note: The Position Transmitter will output the mA signal that corresponds to the actuators current position until the Enter button is pressed
and the “=” sign is flashing. When the “=” sign is flashing, the output will change to the “Span” or Hi Calibration value.

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 span to automatically re-calibrate its output.

Password defines the password required to enter the SETUP mode in order to change any control parameters. The default value of
00000 indicates no password is required. If a value is entered into Password other than the default value, future entry into Setup
mode will require that the user enter the Password value prior to gaining access to the Setup menus.

Disp displays the version of display software. Example: Disp AA_06.1.2018_AA

Cntrl displays the version of control (CPU) software. Example: AA_12.5.81318

6.1.9 Current Stats Menu and Historic Stats Menu

The CURRENT STATS and HISTORIC STATS menus provide error counters and usage indicators. They offer identical information;
CURRENT STATS parameters can be cleared/zeroed whereas the HISTORIC STATS cannot.

The error counters are provided as an aid to diagnosing a problem. They are particularly useful in identifying intermittent problems
since they record ALL instances of detected errors, rather than just those which result in an “alarmed” condition. They are also useful
in identifying problems associated with actuator “tuning”.

Error counters generally operate only in AUTO mode. Errors detected in SETUP are not recorded. Usage indicators only record in
AUTO mode.

The CURRENT STATS error counters and usage indicators may be reset to zero by the following;

While in SETUP and the counter/indicator to be reset is on display:

Press Enter – the equals sign begins blinking

Press Down – the value field resets to zero

Press Enter – the new count is now zero

Note: If the Up key is pressed prior to step 3, the old count is returned to the display and will be retained if the Enter key is then pressed.

Note: See Appendix F. Errors and Error Displays for more information.

6. Modes of Operation & Control Parameters

 49 6. Modes of Operation & Control Parameters

Messages in CPU Motor Errors: Servo Primary Booster Faults:

Display Error Status: PSrv_Flt: SBstFlt:
CS bad: PSrvReset: SBstRest:
MFB bad: SBstMTRTemp:
P MTRTemp:
Rdnt_FB bad: SBstResCable:
PResCable: SBstDRV Temp:
Fb Offset:
P DRV Temp: SBstReplc DRV:
Slc Fb bad:
Slc stop: P Replc DRV: SBstMTR Cable:
APres_Low: P MTR Cable: SBstMTR Short:
APres_Bad: P MTR Short:
Accum_Time:
Dual Servo Booster Faults:
Accumulator Conflict: (A_Conflict) Dual Servo Faults: DSBstFlt:
Stall: DSBstReset:
DSrvFlt:
Dir error:
Inval PST: DSrvReset: Primary Induction Drive Faults:
PSTTimELP: D MTRTemp: PInducFlt:
OpPresbad or ClPresbad: DResCable: PIndReset:
Clock Bat: D DRV Temp:
Delta Alarm: D Replc DRV:
Induction Booster Drive Faults:
Delta Warn: IBstFlt:
D MTR Cable:
IBstReset:
Power Supply Errors: D MTR Short:
-5Bad: Primary Stepper Drive Faults:
AC High
Accumulator Servo Faults: PStpFlt:
AC Low ASrv Fault: PStpReset:
+15Bad: ASrvReset:
AMTRTemp:
Dual Stepper Drive Faults:
System Configuration Errors: AResCable:
DStpFlt:
No inp bd: DStpReset:
A DRV Temp:
Inval HW:
Inval SC: A Replc DRV: Accumulator Stepper Drive Faults:
PConflict: A MTR Cable: AStpFlt:
No PMotor: A MTR Short: AStpReset:

6.2 Auto Mode

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

6.2.1 Display Fields in Auto Mode

Field 1 displays the Operating mode.

Field 2 displays the unit status.

Field 3 displays the parameter position or alternate.

Field 4 separates fields 3 and 5 with “space = space”.

Field 5 shows the value for the parameter.

Field 6 shows the local time.

Field 7 shows the date.

Figure 6.2.1
Field 8 shows Bluetooth.

Field 9 shows motor on/off.

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6.2.2 Display Information

AUTO (Field 1) indicates the unit is in Auto mode, standard operation.

Auto – Bt (Field 1) indicates Auto mode with Bumpless transfer in progress. Refer to the CONTROL menu.

Auto – mm (Field 1) refers to Auto mode with minimum modulating active. Refer to the CONTROL menu.

Auto – Rchg (Field 1) indicates the unit is in Auto mode with accumulator Recharge cycle in progress. Refer to the DRIVES menu.

Auto – Trip (Field 1) indicates the unit is in Auto mode with the Trip input active. Refer to the INPUTS menu.

Status:OK (Field 2) or an error/warning message indicates the status of the unit. Refer to the Current Stats menu.

Position (Field 3) identifies the value displayed in Field 5.

Value (Field 5): Low if current position is more than 0.5% below Position Lo

0.0 to 100.0 if current position is between Position Lo and Position Hi

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

Note: Low or High indicates overtravel past Position Hi or Position Lo setting due to spring/accumulator driven operation.

If set up for Reverse Acting: Value (Field 5): Low if current position is more than 0.5% above Position Lo

0.0 to 100.0 if current position is between Position Lo and Position Hi

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

Position value may display the following in the situations stated:

Unknwn (Field 5) if the feedback signal from the actuator to the Control enclosure is not present.

Seated (Field 5) if the seat load cylinder is at the “seated” position

6.2.3 Parameter Viewing

In Auto mode the Control Parameters may be viewed (but not altered) by using the Up or Dn keys. The Down key pressed displays
“Live Control Signal”.

The next 2 presses of the Down key displays the “Live OPEN PRES” (Open Pressure Transducer) and “Live CLOSE PRES” (Close Pressure
Transducer) values in psi. Successive presses of the Down key step the display through the SETUP menus.

The UP key pressed displays the current “Live Deviation”.

Successive presses of the UP key step the display through the SETUP Menu from CURRENT STATS. A 5-second timer reverts the display back to
current Position parameter if no keys presses are detected. Holding the key depressed displays the current parameter indefinitely.

Control Sig {Live Control Signal} (Field 4) identifies the value of the Analog Control Signal. The display is 0 -100 % for easy comparison
with the Position display.

Control Sig = ‘None’(Field 5):, when parameter Signal TYPE does not equal Analog.

Low when current signal is more than 0.5% below Signal Lo.

0-100% Active 4-20 mA signal is applied and is in between Signal Lo and Signal Hi.

High when current signal is more than 0.5% above Signal Hi.

Unknwn when control signal is not applied.

6. Modes of Operation & Control Parameters

 A-1 A. Mechanical Limit Switches

A. Mechanical Limit Switches

The mechanical limit switches are independent devices installed on the yoke of the linear units and in the feedback housing area
of rotary or drive units. Electrical connections are made directly to the switches independent of REXA electronics. Position will be
indicated regardless of actuator power status.

A.1 Linear
A.1.1 General Specifications
Quantity: 2 or 4

Type: Single Pole, Double Throw (SPDT), Form C.

Rating: 5 amp @ 24 Vdc, 0.5 amp @ 125 Vdc,

10 amp @ 110 Vac - resistive

Differential Travel (Hysteresis): 5/16”

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

GRP. A, B, C & D.

Connection: ½”-14 NPT, screw terminals

Optional DPDT Limit Switches

Quantity: 2 or 4
Figure A.1 Linear Limit Switches
Type: Double Pole Double Throw (DPDT), Form CC

Rating: 3 amp @ 24 Vdc, 0.5 amp @ 125 Vdc,

10 amp @ 110 Vac - resistive

Differential Travel (Hysteresis): ¼˝

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

GRP. A, B, C & D.

Connection: ½˝-14 NPT, screw terminals

A.1.2 Linear Wiring

Remove the access plate by unscrewing the four slotted screws on the bottom of the unit. Thread the cable through the ½˝ NPT fitting
and connect to the appropriate Normally Open (NO), Normally Closed (NC) and Common (C) screw terminals. The cable should be
grounded in accordance with Local and National Electrical Code. Make sure that the gasket is in place and tightly seal the cavity.

A.1.3 Linear Adjustment

Loosen the two mounting screws approximately 1½ to 2 turns and slide the entire switch to the required position. Securely retighten
the screws.

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A.2 Rotary
A.2.1 General Specifications
Quantity: 2 or 4

Type: Single Pole, Double Throw (SPDT)

Rating: 10 amp @ 24 Vdc, 0.5 amp @ 125 Vdc,

10 amp @ 110 Vac - resistive

Differential Travel (Hysteresis): 5½ ˝

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

GRP. A, B, C & D (optional).

Figure A.2 Rotary Limit Switch Schematic
Connection: Within the feedback housing (½ ˝ NPT) screw terminals

Optional DPDT Rotary Limit Switches

Quantity: 2

Type: Double Pole, Double Throw (DPDT), Positive Pressure

Rating: 0.3 amp @ 125 Vdc, 0.15 amp @ 250 Vdc,

10 amp @ 125 or 250 Vac

Differential Travel (Hysteresis): 5½ ˝

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

Connection: Directly to screw terminal on the switch.

Figure A.2 Rotary Limit Switch Schematic

A.2.2 Rotary Wiring

Remove the cylinder feedback cover (over the cylinder pinion)
by unscrewing. Refer to Figure A.2.3. Take care to keep threads
clean and free from damage. Thread the cable through the ½ ˝ NPT
fitting and make connections directly to the microswitches. Refer
to Figure A.2. The cable should be grounded in accordance with
Local and National Electrical Code.

A.2.3 Rotary Adjustment

For adjustment, the switch cam can be relocated by loosening the
set screw and repositioning. Make sure that the O-ring gasket is in
place and tightly seal the cavity. (See Figure A.2.3)

Figure A.2.3 Rotary Limit Switch

A. Mechanical Limit Switches

 A-3 A. Mechanical Limit Switches

A.3 Rotary Valve Position Monitor (VPM)

A.3.1 General Specifications
The Rotary Valve Position Monitor (VPM) or Feedback assembly consists of a Aluminum housing
containing a non-contacting (Touchless) analog sensor. The sensor is coupled to the rotary cylinder
by means of a magnetic induction and transmits the actuator position to the CPU.

The Rotary Valve Position Monitor (VPM) has one(1) sensor and up to four (4) optional SPDT Rotary
Limit Switches:

Figure A.3.1.1: REXA VPM Sensor

The touchless sensor, mounted on a bracket, has 3 wires; Blue/white for output, Black for ground
and Red for supply, all connected to a terminal block.

Input: 14.8 – 30 VDC Output: 4-20 mA

Switches

Type: Hermetically Sealed, Single Pole, Double

Throw (SPDT), Positive Pressure

Rating: 3.0 AMPS @ 28 VDC, 1.0 AMP @ 115 VAC

Figure A.3.1.2: Sensor,
Environmental: CSA/IEC, Class1, Div.2 or Zone 2,
Terminal & Switches
IP66 (NEMA 4),

Connection: Directly via terminal Blocks

A.3.2 Adjustment
Any adjustment to the Rotary sensor 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 fail position.

Figure A.3.1.3:
Limit-Switches 11HM1

Figure A.3.2:
Rotary Touchless sensor

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Xpac Series 3 - Installation and Operation Manual - 9/22 B-1

B. Stem Connection & Seat Loading Methods

B.1 Theory of Operation

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

B.2 Elastic Coupling

For applications that extend or retract against a hard stop, linear Xpac actuators are provided with an “elastic coupling” for connecting
the driven device to the actuator. The elastic coupling contains a set of disc springs which are pre-compressed to approximately
80% of the rated thrust for fail-in-place units and 50% of the rated thrust for spring fail actuators.

The coupling provides a visual indication of compression (seat load) and should be compressed to its rated mark when the driven
device is at the end of travel. At that point, the load on the driven device is approximately the net rated output of the actuator.
Lower rated couplings are available for applications that require reduced seat load.

The force indicator on the elastic coupling is a pin captured in a slot on the side of the coupling. As the coupling compresses, the
pin slides in the slot. A scribed line marks the rated output position.

Figure B.2-1 Preloaded Coupling Figure B.2-2 Rated Load Coupling

Enclosed spring couplings (not shown) have a small telltale pin protruding from the top or bottom. As the coupling compresses, the
pin is drawn into the coupling. When the pin is flush with the coupling, it is at its rated output.

Note: The output of each coupling may be verified through the pressure gauges.

Note: To translate pressure gauge readings into actuator output, use the following formula:

For additional output calculation data, refer to Appendix O.

B. Stem Connection & Seat Loading Methods

 B-2 B. Stem Connection & Seat Loading Methods

B.3 Seat Loading Cylinder

On larger size units the forces are too great to use a mechanical elastic coupling. Instead, a smaller Seat Loading Cylinder (SLC) with
a spring load is hydraulically connected to the actuator cylinder as shown Figure B.3.

The Seat Loading Cylinder utilizes a pre-compressed load equivalent to 80% (1 600 psi) of the nominal working pressure (2 000 psi). As
the power modulepumps hydraulic fluid into the actuator cylinder, the output shaft will begin to extend. Once the force on the extension
shaft reached the preset 80% of the actuator’s rated output, the pressure in the top of the actuator cylinder will reach the limit that begins
to compress the spring on the seat load cylinder. This will occur when the driven device reaches its end of stroke. As the pressure builds
within the actuator cylinder, oil flows into the SLC, designated by the high pressure flow arrow and retracts the SLC shaft. When the spring
is compressed to the full nominal working pressure, the position feedback of the SLC will trigger the power module to shut off. The rated
actuator output is now applied to the driven device and retained within the cylinders by the Flow Matching Valves.

Seat Load Cylinder

Figure B.3 Seat Loading Cylinder

B.3.1 Mechanical Installation
The Seat Loading Cylinder is mounted to the side of the main cylinder at the factory. All hydraulic piping and spring preload will be
complete. Mechanical installation is not required.

B.3.2 Electrical Installation

Operation of the Seat Loading Cylinder requires the connection of a feedback cable between the SLC and the control enclosure.
The standard cable consists of a red, white and black wire and a tinned copper ground wire. Each individual wire is 18 AWG. The
feedback cable is not restricted by distance.

The feedback connection is made directly to the screw terminals on the feedback printed circuit board. Remove the four cap screws
cover using care not to damage the internal components. Feed the cable through the ½ inch NPT opening. Wiring connection is
made directly to the feedback printed circuit board per Figure B.3.2. Replace the cover on the cylinder and securely fasten. Refer
to the Electrical Installation section.

Refer to certified electrical drawing for wiring details.

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Table B.3.2 SLC Connections

SLC—½ inch NPT on cylinder (Screw Termination)
Signal Name Wire Colors Terminal
+15 Vdc Red 15V
Feedback (+) White 4-20
Feedback (-) Black GND

B.4 Solenoid Auto-Seating

For linear valve applications that require fail-safe in the same direction as the seated position, the elastic coupling and seat load
cylinder are considered to be redundant and unnecessary. Using an elastic coupling on a spring fail or accumulator fail REXA is like
using a spring in series with another spring. For these applications REXA handles the seat loading with software that automatically
controls the solenoid operation as the actuator positions close to the seat. This control menu parameter is called Solenoid Seat (Sol.
Seat). The software concept is similar in operation to the Min Mod functionality. Rather than use the motor to drive to the seat, once
the actuator reaches a position close to the seat the solenoid valve(s) open and the remaining travel is accomplished by using the
stored energy (spring or accumulator) to drive the valve into the seat.

B.5 Calibration
Operation of the actuator is the same as a unit with an elastic coupling. The only difference is at the
Seated Position. Instead of compressing a coupling, the spring on the SLC is compressed until the
indicator on the SLC leg is at the seated point. See Figure B.5-1.

Position Lo is set by moving the stem to the corresponding Signal Low Extend Position. Signal low
position is the “SEAT” position. The seat load cylinder flag must line up with the “SEAT” indicator mark
on the spring housing cover. The “SEAT” indicator mark is factory set for each application. The preset
tension of the spring should not be changed without consulting the REXA factory.

With Position Lo on the display, press the (E)NTER key. = will begin to blink. Using the Scroll Up and
Scroll Down keys, position the actuator to the desired point and press (E)NTER again. The displayed Figure B.5-1
value will be recorded as the Position Low endpoint. SLC Indicator–Seated

Position Hi is set by moving the stem to the corresponding Signal High, Retract Position.

B.5.1 Reverse Acting Calibration

Position Lo is set by moving the stem to the corresponding Signal Low Retract Position.
Signal Low Position is the “SEAT” Position. The seat load cylinder flag must line up with
the “SEAT” indicator mark on the spring housing cover. The “SEAT” indicator mark
is factory set for each application. The preset tension of the spring should not be
changed without consulting the REXA factory.

Position Hi is set by moving the stem to the corresponding Signal High Extend position.
Reset Switch
With Position Hi on the display, press the (E)NTER key. = will begin to blink. Using the
Scroll Up and Scroll Down keys, position the actuator to the desired Extend point and
press (E)NTER again. The displayed value will be recorded as the Position Hi endpoint.
When calibration is complete, and before returning to “AUTO” mode, depress the
RESET button located on the top of the REXA CPU board. This will set the new seated
value as the SLC target. See Figure B.5-2.

Figure B.5-2 Reset Switch

B. Stem Connection & Seat Loading Methods

 C-1 C1. Standard Accumulator Fail-Safe

C1. Standard Accumulator Fail-Safe

C1.1 Theory of Operation

System operation is based on a piston type accumulator with nitrogen gas on one side of the piston and oil on the other.

The Standard Accumulator Fail-Safe is identified by a blue solenoid (see figure C1).

Figure C1.1 Standard Accumulator Fail-Safe

C1.1.1 Trip Function
Refer to Figure C.1.1-A (Standard Accumulator), Trip Collection
Bottle
Condition, to follow the fluid flow path during a
trip. The arrows indicate the flow direction. Under a
trip condition or loss of electric power, two solenoid Actuator Cylinder
Isolation Valve
valves open simultaneously. One solenoid allows oil
Trip Solenoid
under pressure from the accumulator to be released
and enter the failure side of the actuator driving it in Port A (Unit will trip
on power loss)
Power Module
the fail direction. The other solenoid allows the oil to A
C

be displaced from the opposite side of the cylinder Trip Speed

Optional Plumbing
Port B (Unit will not
B

Control Valve
into an collection bottle. To control the fail speed a trip on power loss)

needle valve is installed on the outlet of the second

solenoid valve.

C1.1.2 Recharge Function

Reference Figure C.1.2-B to follow fluid path during
recharge of Standard Accumulators. When the trip
condition ends or power is restored, a pressure
transducer signals that the CPU has low pressure
Accumulator
in the accumulator. This signal tells the CPU to run Pressure Gauge
the power module in the direction required to drive
Accumulator Bottle
the actuator in the fail direction. Since the actuator Trip Solenoid

cylinder is already at the end of its travel, the oil being

pumped from the collection bottle by the power
module will be allowed to flow into the accumulator.
When the proper recharge pressure is reached, the
CPU stops the power module and closes the solenoid Pre-charged Nitrogen Gas
valves. Normal operation is now resumed and the
actuator will follow the control signal. Figure C1.1.1 (Standard Accumulator) Trip Condition

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Xpac Series 3 - Installation and Operation Manual - 9/22 C-2

Collection Bottle

Actuator Cylinder
Isolation Valve

Trip Solenoid

Port A (Unit will

Power Module trip on power loss)

Optional Plumbing
Trip Speed
Control Valve
Port B (Unit will not
trip on power loss) A
C

Trip Solenoid

Accumulator
Pressure Gauge

Accumulator Bottle

Pressure Transducer
Pre-charged Nitrogen Gas

Figure C1.1.2 Recharge Condition

C1.2 Accumulator Control Parameters
Five parameters in the electronics are used to control accumulator functions. These may be found under the Drives menu and are:
Rechrg Pres, Warn Pres, Rechrg Time, Accum Dr and Accum Pres.

Reference the DRIVES Menu in Modes of Operation & Control Parameters.

C1.3 Recharging
The recharge cycle will only occur if:

1. The CPU is in the Auto mode when power is restored after a loss of power or removal of trip signal,

And

2. The pressure transducer output is less than Rechrg Pres

If the CPU is NOT in Auto mode when power is restored or trip signal is removed, the unit must be placed in Auto and the reset
button MUST be pushed.

IMPORTANT: All actuators are shipped in the failed or tripped condition. The actuator may initially power up in Setup
mode. With the trip signal inactive (or not connected), put the actuator in Auto then either press the reset button or
cycle power off and back on. The actuator will go through a fail cycle, a re-charge cycle and then return to following
the control signal. If this operation is not performed, the actuator will follow the control signal, but the accumulator
will remain uncharged, rendering the actuator incapable of performing a trip or fail operation. However, a low
pressure warning will indicate insufficient pressure to perform a fail operation.

C1. Standard Accumulator Fail-Safe

 C-3 C1. Standard Accumulator Fail-Safe

C1.4 Manual Override

Accumulator actuators with solenoid valves are supplied with manual override
levers. This feature enables a way to manually change states of the solenoid
valves with electrical power off or in trip mode. Units are shipped from the
factory with the solenoid override levers in position A (Figure C1.4-1).

They must be in this position for normal operation of the actuator. To use the
handwheel during a power off or trip situation both solenoid override levers
must be moved to position B.

Once both overrides are moved to position B, the handwheel may be operated
in a normal manner (Refer to Appendix M, Manual Operators). After handwheel
use, and prior to returning the actuator to normal service, (power restored or trip
signal removed) both solenoid override levers must be returned to position A. Figure C1.4-1 Solenoid Manual
Override Levers (Position A)
NOTE: When returning the levers to the normal open position the actuator will
stroke in the trip direction.

It is recommended that both override levers be safety wired in position A when

the handwheel is not in use.

For operation of Manual Override, refer to Appendix M, Manual Operators.

WARNING: After using the handwheel, the overrides must be returned

to the A position or the unit will not operate correctly when power is
restored or trip signal removed. If only one override is returned to the
A position after a trip, damage to the power module may occur.

C1.5 Discharging
There will be times that it is necessary to fully discharge the oil-side of the
accumulator system; such as when maintenance is being performed. To perform Figure C1.4-2 Solenoid Manual
this task, do the following: Override Levers (Position B)

1. Remove power to the actuator.

2. If the unit is fail-in-place during power loss, place both solenoid valves in position B as shown in Figure C1.4-2.

3. Open the manual bypass located on the front face of the module. Refer to Figure C1.5.

4. Check to ensure that all the pressure gauges read 0 psi.

Gauge Gauge

CW Off CW Off
CCW On CCW On

Bypass

CW Off
CCW On

Figure C1.5-1 Bypass Drawing

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C2. Online Recharge Accumulator Fail-Safe

C2.1 Theory of Operation

System operation is based on a piston type accumulator with nitrogen gas on one side of the piston and oil on the other. The Online
Accumulator Fail-Safe is identified by a recharge module, that consists of either a stepper or servo motor, attached to a solenoid and
manifold assembly (see figure C2).

Figure C2.1 Online Accumulator Fail

C2.1.1 Trip Function

Refer to Figure C2.1.1-B (Online Recharge Accumulator), Trip Condition, to follow the fluid flow path during a trip. The arrows
indicate the flow direction.Under a trip condition or loss of electric power, the solenoid valve opens (deenergizes), allowing the
accumulator pressure to pilot open two PO check valves. Accumulator pressure then flows from the accumulator “ACC” to the high
pressure port “HP” to move the actuator by displacing oil in the low pressure port “LP” through the Trip Speed Control Valve into an
auxiliary expansion chamber. The Trip Speed Control Valve integral to the flow control manifold is used to control the fail speed.

If the system is tripped with a trip signal, the system will recharge the accumulator as soon as the actuator has reached its trip
position; this allows the system to readily modulate after removal of the trip signal.

C2. Online Recharge Accumulator Fail-Safe

 C-5 C2. Online Recharge Accumulator Fail-Safe

Figure C2.1.1 Trip Condition

C2.1.2 Recharge Function
Reference Figures C2.1.2-B, C2.1.2-C and C2.1.2-D for the Online Recharge Accumulators.

After a trip condition, the Online Recharge Accumulator drives the accumulator to the fail direction to charge the accumulator. The
solenoid is always closed (energized) and both the power and the recharge modules participate in driving the motor towards the
fail direction and in recharging the accumulator.

Figure C2.1.2-A Recharge After Trip Condition

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During normal operation, if the accumulator pressure falls below Rechrg Pres -100 psi, the online recharge module pumps the oil
from the reservoir to top off the accumulator pressure to the proper recharge pressure set by Rechrg Pres.

Figure C2.1.2-B Online Recharge to Top Off Accumulator Pressure

Recharging of the accumulator per Figure C2.1.2-C can occur simultaneously to modulating of the actuator per C2.1.2-D in either
the PL or PH directions.

Figure C2.1.2-C Modulation to Follow the Control Signal

C2.2 Accumulator Control Parameters
Six parameters in the electronics are used to control accumulator functions. These may be found under the Drives Menu and are:

Rechrg Pres, Warn Pres, Rechrg Time, Power Fail, Accum Dr and Accum Pres.

C2. Online Recharge Accumulator Fail-Safe

 C-7 C2. Online Recharge Accumulator Fail-Safe

C2.3 Recharging
There are two conditions where the recharge cycle will occur as follows:

Condition 1 - The CPU is in the Auto mode when power is restored after loss of power or removal of trip signal AND the pressure
transducer output is less than the Rechrg Pres - 100 psi.

Note: Under this condition, both the Power and the Online Recharge Modules will participate in the recharge of the accumulator.

Condition 2 – When in Auto Mode and the accumulator pressure drops below Rechrg Pres - 100 psi, the Online Recharge Module
will recharge the accumulator. Module will recharge the accumulator. In the Auto Mode, pressing the reset button will momentarily
move the actuator to the Fail Direction and turn on both the Power and Recharge Modules to recharge the accumulator if the
accumulator pressure is less than the Rechrg Pres - 100 psi.

C2.4 Manual Override

The online accumulator actuators can be manually operated (with a hand wheel or hand pump) by following the procedures below
while referring to Figure C2.4-3 (Online Recharge Actuators):

1. Close shut-off valve (Item 1) to isolate the accumulator pressure.

2. Unlock the Trip Speed Control Valve (Item 2) by turning the 9/16 jam nut counter clockwise. With a 5/32 Allen wrench, turn
the adjustment knob clockwise completely in to shut off the valve. Note the number of turns in.

3. Open the bypass on the Recharge Module (Item 3) for 10 seconds to equalize the pressures within the solenoid valve
manifold. After 10 seconds, close the bypass.

The system is now ready for operation with either the hand wheel/drill drive or the manual pump (see figure...). After the manual
override operations are complete, return the system to its normal operation by opening the shut-off valve (Item 1) and setting the
Trip Speed Control Valve (Item 2) to its original open position.

WARNING! If there is NO power to the solenoid, opening the shut-off valve (Item 1) will connect the actuator to high pressure.
Opening the Trip Speed Control Valve (Item 2) to its original position will move the actuator towards the Fail Direction. To
ensure the system does not trip to the Fail Direction, ensure that there is power to the solenoid.

Figure C2.4 Manual Override Condition

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C2.5 Discharging
There will be times when it is necessary to fully discharge the oil-side of the accumulator system; such as when performing
maintenance. For the Online Recharge Accumulator, one of two steps can be done to discharge the accumulator pressure.

Note: Discharging using the manual bypass (item 3) on the online recharge module will not move the acuator.

1. Discharge when the Actuator Power is removed.

a. Remove power to the actuator to fail the unit in the Trip Condition.

b. Open the bypass (item 3) on the online recharge module. Refer to Figure C2.5-2. The accumulator pressure will discharge
into the reservoir bottle. When the Accumulator gauge reads 0 psi, all accumulator pressure has been completely
discharged.

2. Discharge when in the Calibration Mode.

a. Ensure that the actuator is in the desired operating position.

b. Place the CPU in Calibration Mode.

c. Open the bypass (item 3) on the online recharge module. Refer to Figure C2.5-2. The accumulator pressure will discharge
into the reservoir bottle. When the accumulator gauge reads 0 psi, all accumulator pressure has been completely discharged.

Figure C2.5 Manual Override Condition

C2. Online Recharge Accumulator Fail-Safe

 D-1 D. Booster Pump Configuration

D. Booster Pump Configuration

D.1 Theory of Operation

Booster Pump Configurations utilize an Xpac power module and a large capacity “Booster Pump”. The power module provides fine
positioning, while a volume booster pump provides the speed for large or coarse position changes. This dual pump operation
allows REXA to extend its unique capabilities to very high thrust or torque units and high-speed operation without sacrificing
position accuracy.

Two sizes of BOOSTER PUMPS are available: the P9 and the P40. The P9 is used in combination with the D size power module to
provide 5 times the capacity of a D size power module or 2.5 GPM. A P40 with D size power module has the pumping capacity for
11 GPM.

D.2 Mechanical Installation

An Xpac Series 3 with the Booster Pump Configuration has no special installation procedure. Therefore, the standard installation
should be followed.

D.2.1 Control Enclosure

The major electrical components are located in a NEMA 4X enclosure. They have a wide temperature range¹ (-40 °F to 120 °F1 [-40 °C
to +49 °C]) and can be field installed at a convenient location. Avoid areas subject to excessive vibration or heat. To reduce the
possibility of water incursion, we recommend that any fitting be pointed downward.

Ambient temperature only. Direct solar heat load must be avoided.

1

D.3 Electrical Installation

The Xpac Series 3 consists of two major components, the Electraulic actuator (cylinder and power module) and the control enclosure.
The actuator is installed on the driven device, while the enclosure is remotely mounted. Connecting them are the motor power,
resolver, feedback and module cables. Some cables may not be run within the same conduit or seal-tite flex hose. Preferred wiring
procedures recommend that power voltages (motor power and module cables) be kept separate from low level signal lines (resolver
and feedback cables). User connections of electric power and control signals are made at the enclosure.

Refer to Appendix P, Interconnect Diagrams.

Important!
• Motor power and motor resolver cables for the power module and booster pump motors must be shielded! The shield of
each is connected to the green ground screw on the back panel of the control enclosure only.

• The motor resolver signals are low level voltages. The motor resolver cables must be kept separate from the motor power
cables or any other high power wiring. However, the resolver cables may be run with the feedback cable or other low
power conductors.

• Failure to follow the above may inhibit the proper operation of the actuator.

D.4 Control Parameters

Refer to DRIVES menu, Modes of Operation & Control Parameters.

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Xpac Series 3 - Installation and Operation Manual - 9/22 E-1

E.1 Bluetooth Graphical User Interface

E.1 Bluetooth Connection

Complete installation utilizing the installation wizard. Desktop Icon (Figure 1) will launch the GUI.

Figure 1.1 Desktop Icon

When the Bluetooth program launches you will first see the “Bluetooth Connection’ screen and signal strength will be indicated on
the left hand side of the screen. Clicking the “Search” button will scan the area for Available Bluetooth signals from REXA units.

Figure 1.2 Initial Screen

When the search is complete GUI will show the actuators found. Actuators will be identified by REXA serial number. Select the
actuator you wish to connect to and click the “Connect” button.

E.1 Bluetooth Graphical User Interface

 E-2 E.1 Bluetooth Graphical User Interface

Figure 1.3 Bluetooth Connection

The connection process will begin and the program will prompt you to enter the password to connect. Enter password and click “Ok”.

Figure 1.4 Search for Actuators

Once connected the GUI will display all pertinent information related to the selected actuator. Details shown are: model number,
tag number, commission date, device clock, software version, duration and signal strength.

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Xpac Series 3 - Installation and Operation Manual - 9/22 E-3

Figure 1.5 Enter Pairing Key

E.2 Status
The “Status” screen indicates the current status of the connected actuator. Current operation mode, operational status, control
signal, actuator position, active feedback loop, warning status, alarm status, motor starts, actuator strokes, total auto time, 3 month
average position. Displaying actuator output thrust or torque is an available option.

Figure 2 Status

E.1 Bluetooth Graphical User Interface

 E-4 E.1 Bluetooth Graphical User Interface

E.3 PST
The “PST” screen indicates the status of the last PST event (pass/fail) and allows for the trigger of a manual PST event if desired. The
PST function will only appear in the GUI if the actuator supplied is equipped with PST construction and programming.

Figure 3 PST
E.4 Diagnostics
The “Diagnostics screen indicates the occurrence of error related events (Example: CS Bad). Each error is recorded with a time stamp that
shows when the error occurred and when the error was cleared. Adjustable warning and alarm status is also viewable. These include:
accumulator warning pressure, accumulator recharge pressure, delta pressure output warning and delta pressure output alarm.

Figure 4 Diagnostics

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Xpac Series 3 - Installation and Operation Manual - 9/22 E-5

E.5 Calibration
The “Calibration” screen allows the user to view calibrated parameters of the REXA actuator via Bluetooth control.

Figure 5 Calibration
E.6 Configuration
The “Configuration screen allows the user for view all pertinent values that the actuator is currently programmed to.

Figure 6 Configuration

E.1 Bluetooth Graphical User Interface

 F-1 F. Errors and Error Displays

F. Errors and Error Displays

The following are the error messages which appear on line 1 in place of Status:OK when one or more errors are detected. If more
than one error is active, each is displayed at 1 second intervals in a repeating fashion. By means identified in the “Cleared by”
sections which follow. To fix some of these alarm code errors it may be necessary to refer to the Trouble Shooting and Repair manual.
Messages in CPU Display Error Status:
CS bad:
Cause: The analog Control Signal is below 2.5 mA; either the (+) or (-) 15 fail is set, or A/D fail is set.
Indicators: Alarm and Warning relays open. CS Bad is displayed. Actuator will move to Failsafe position.
Cleared by: Self clearing when Control Signal > 2.5 mA, or when 15 fail or A/D fail clears.
MFB bad:
Cause: The actuator’s main Feedback is below 2 mA; (+) 15_fail is set, or A/D fail is set.
Indicators: Alarm and Warning opens. MFB_Bad is displayed. Actuator will not move.
Cleared by: Self clearing when Feedback > 2 mA, or when 15 fail or A/D fail clears.
Rdnt_FB bad:
Cause: The actuator’s redundant feedback is below 2 mA.
Indicators: Warning Relays open. Rdnt FB Bad is displayed. Actuator will move.
(Only warning if Redundant Feedback Bad only. Alarm when both MFB Bad and Rdnt FB Bad have failed. Actuator will not move if
MFB_Bad also).
Cleared by: Self clearing when Feedback > 2 mA
Fb Offset:
Cause: The actuator’s main Feedback and Rdnt FB have a > 10% difference.
Indicators: FB_Offset is displayed. Actuator will move.
Cleared by: Self clearing when Feedback offset < 7%.
Slc Fb bad:
Cause: The Feedback signal from the Seat Load Cylinder is less than 2 mA.
Indicators: Alarm and Warning relays open. Slc Fb bad is displayed. Actuator will not move.
Cleared by: Self clearing when Feedback > 2 mA.
Slc stop:
Cause: The actuator has detected a “Seated” position from the seat load cylinder feedback, but the main cylinder is ±1% from
its “Seated” position.
Indicators: Warning relay opens. Slc stop is displayed.
The actuator continues with normal operation; however, the main cylinder may not seat properly.
Cleared by: Any control signal change which effects movement in the opposite direction in which the stop occurred will clear the error.

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Xpac Series 3 - Installation and Operation Manual - 9/22 F-2

APres_Low:
Cause: The accumulator pressure is below the value set in parameter Warn Pres.
Indicators: Warning relay opens. Pres low is displayed. Actuator continues to operate normally.
Cleared by: Successful Accumulator recharge cycle.
APres_Bad:
Cause: The accumulator’s pressure transducer is out of range if the 4 - 20 mA signal is less than 3 mA or greater than 21mA.
Indicators: Warning relay opens, APres_bad is displayed. Actuator continues to operate normally.
Cleared by: Cleared when transducer signal is greater than 3 mA or less than 21 mA.
Accum_Time:
Cause: The accumulator did not complete a full recharge in time set by Rechrg_Time. of 10-999 sec.
Indicators: Warning relay opens. Accum_Time is displayed. Actuator continues to operate normally.
Cleared by: Cleared successful Recharge cycle
Accumulator Conflict: (A_Conflict)
Cause: Sys_Config has a Stepper or Servo already for On-Line Accumulator.
Indicators: Invalid_Hardware is displayed
Cleared by: Correct hardware configuration install, and successful Sys_Config.
Stall:
Cause: After five attempts the actuator was unable to move .1% of stroke within 5 seconds. (Total time of 25 seconds)
The “Seated” position was reached on the Seat Load Cylinder while the position of the main cylinder was greater than 1% above
Position Lo.
Indicators: Alarm and Warning relays open. Stall is displayed. Actuator will not move.
Cleared by: CPU Reset or any control signal change which effects movement in the opposite direction of the stall will clear the stall error.
Dir error:
Cause: The actuator was detected moving in the wrong direction.
Indicators: Alarm and Warning relays open. Dir error is displayed. Actuator will not move.
Cleared by: Cleared by cycling main power on, by pushing the CPU reset switch, or entering the Setup mode.
Inval PST:
Cause: A PST cycle was initiated when the Position was not at 100%.
Indicators: Inval_PST is displayed
Cleared by: Suscessful PST cycle
PSTTimELP:
Cause: A PST cycle was initiated but did not complete in time set in PST_Time.
Indicators: PSTTimeELP is displayed
Cleared by: Suscessful PST cycle
OpPresbad or ClPresbad:
Cause: The open or close pressure transducer is out of range. The transducer is considered out of range if the 4-20 mA signal is less than 3 mA.
Indicators: Warning relay opens. Op or Cl Pres bad is displayed.
Actuator continues to operate normally in Auto mode.
Cleared by: Transducer signal being greater than 3 mA.
Note: Not applicable if pressure transducers are powered by and wired directly to the DCS.

F. Errors and Error Displays

 F-3 F. Errors and Error Displays

Clock Bat:
Cause: Battery voltage low, Indicates 10 year timer has expired
Indicators: Clock Bat displayed
Cleared by: Replace clock battery (located on power board) and reset battery timer in the calibrate menu.
Delta Alarm:
Cause: Indicates delta pressure exceeded alarm limit.
Indicators: Alarm and warning relays open. Pressure Output is displayed.
Cleared by: Actuator output returning to below alarm range.
Delta Warn:
Cause: Indicates delta pressure exceeded warning limit.
Indicators: Warning relay open. Pressure Output is displayed.
Cleared by: Actuator output returning to below warning range.
Note: Not applicable if pressure transducers are powered by and wired directly to the DCS.

Power Supply Errors:

-5Bad:
Cause: The (-)5 volt power supply is out of range if it exceeds a (+) or (-) 10% error band.
Indicators: Alarm and Warning relays open. -5V_Bad is displayed. Actuator will not move.
Cleared by: CPU will attempt to clear fail error until fault condition is corrected.
If condition not cleared, replace Power Board.
AC High
Cause: Main Power supply into the actuator rises above 131VAC on 115VAC rated unit or rises above 261VAC on 230VAC unit.
Indicator: Actuator will log events in the counters of the REXA GUI or over any digital protocol such as HART. Relay warning and
alarm relay indicators will not indicate these events.
Cleared by: Once the AC power goes below 128VAC on 115VAC rated unit or goes below 256VAC on 230 VAC units.
AC Low
Cause: Main Power supply into the actuator drops below 101VAC on 115VAC rated unit or drops below 193VAC on 230VAC unit.
Indicator: Actuator will log events in the counters of the REXA GUI or over any digital protocol such as HART. Relay warning and
alarm relay indicators will not indicate these events.
Cleared by: Once the AC power goes above 104VAC on 115VAC rated unit or goes above 197VAC on 230 VAC units.
+15Bad:
Cause: The (+)15 volt power supply is out of range if it exceeds a (+) or (-) 10% error band.
Indicators: Alarm and Warning relays open. +15V_Bad is displayed. Actuator will not move.
Cleared by: CPU will attempt to clear fail error until fault condition is corrected.
If condition not cleared, replace Power Board.
System Configuration Errors:
No inp bd:
Cause: 1. Signal Type can not be set to 1 Cont, 2 Cont, a contact input board is not installed or is faulty.
Indicators: Alarm and Warning relays open. No input bd is displayed.
Cleared by: Changing the Signals menu parameter(s), or (with power off ) installing the required board.

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Xpac Series 3 - Installation and Operation Manual - 9/22 F-4

Inval HW:
Cause: Sys_Config has hardware connected that is not a valid configuration.
Indicators: Inval_HW (Invalid Hardware) is displayed
Cleared by: Correct hardware configuration install, and successful Sys_Config.
Inval SC:
Cause: Sys_Config has hardware, Motor Drivers and Analog Inputs connected that are not a valid configuration for the System
Software installed.
Indicators: Inval_SC (Invalid Software Configuration) is displayed
Cleared by: Correct hardware configuration installed, and successful Sys_Config.
PConflict:
Cause: Sys_Config has discovered 2 Primary Motor Drivers connected, only 1 Primary Motor Driver allowed.
Indicators: PConflict (Primary Motor Driver Conflict) is displayed
Cleared by: Correct hardware configuration installed, and successful Sys_Config.
No PMotor:
Cause: Sys_Config has discovered no Primary Motor Driver connected.
Indicators: No_PMotor (No Primary Motor Driver Installed) is displayed
Cleared by: Correct hardware configuration installed, and successful Sys_Config.
Motor Errors:
PSrv_Flt:
Cause: Fault line from Primary Servo Motor indicating fault state Indicator:
Indicators: PServoFlt. Is displayed. Warning relay opens. The actuator may or may not continue normal operation depending on
actuator construction.
Set up Mode: Actuator will move only if additional motors are available.
Manual Mode: Actuator will move only if additional motors are available.
Auto Mode: Actuator will move only if additional motors are available.
Cleared by: CPU will attempt to reset drive fault error until fault condition is corrected.
PSrvReset:
Cause: At least one motor drive has detected a problem and asserted Drive Fault.
Indicators: PSrvReset is displayed. Warning relay opens.
Cleared by: End of Reset Signal generation by CPU
P MTRTemp:
Cause: The Primary Servo Motor is over temperature.
Indicators: PMTRTemp is displayed. Warning relay opens.
Cleared by: The Primary Servo Motor has returned to normal temperature.
PResCable:
Cause: The Primary Servo Motor Resolver cable has a short or an open.
Indicators: PResCable is displayed. Warning relay opens.
Cleared by: The Primary Servo Motor Resolver cable short or open corrected.

F. Errors and Error Displays

 F-5 F. Errors and Error Displays

P DRV Temp:
Cause: The Primary Servo Motor Driver is over temperature.
Indicators: P_DRV_Temp is displayed. Warning relay opens.
Cleared by: The Primary Servo Motor Driver has returned to normal temperature.
P Replc DRV:
Cause: The Primary Servo Motor Driver has a shorted output.
Indicators: P_Replc_DRV is displayed. Warning relay opens.
Cleared by: The Primary Servo Motor Driver has been replaced.
P MTR Cable:
Cause: The Primary Servo Motor Power cable has a short or an open.
Indicators: P_MTR-Cable is displayed. Warning relay opens.
Cleared by: The Primary Servo Motor Power cable short or open corrected.
P MTR Short:
Cause: The Primary Servo Motor has a short.
Indicators: P_MTR-Short is displayed. Warning relay opens.
Cleared by: The Primary Servo Motor has been replaced.
Dual Servo Faults:
DSrvFlt:
Cause: Fault line from Dual Servo Motor indicating fault state Indicator:
Indicators: DSrvFlt. Is displayed. Warning relay opens. The actuator may or may not continue normal operation depending on
actuator construction.
Set up Mode: Actuator will move only if additional motors are available.
Manual Mode: Actuator will move only if additional motors are available.
Auto Mode: Actuator will move only if additional motors are available.
Cleared by: CPU will attempt to reset Drv fault error until fault condition is corrected.
DSrvReset:
Cause: At least one motor drive has detected a problem and asserted Drive Fault.
Indicators: DSrvReset is displayed. Warning relay opens.
Cleared by: End of Reset Signal generation by CPU
D MTRTemp:
Cause: The Dual Servo motor is over temperature.
Indicators: DMTRTemp is displayed. Warning relay opens.
Cleared by: The Dual Servo motor has returned to normal temperature.
DResCable:
Cause: The Dual Servo Motor Resolver cable has a short or an open.
Indicators: DResCable is displayed. Warning relay opens.
Cleared by: The Dual servo Motor Resolver cable short or open corrected.

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D DRV Temp:
Cause: The Dual Servo Motor Driver is over temperature.
Indicators: D_DRV_Temp is displayed. Warning relay opens.
Cleared by: The Dual Servo Motor Driver has returned to normal temperature.
D Replc DRV:
Cause: The Dual Servo Motor Driver has a shorted output.
Indicators: D_Replc_DRV is displayed. Warning relay opens.
Cleared by: The Dual Servo Motor Driver has been replaced.
D MTR Cable:
Cause: The Dual Servo Motor Power cable has a short or an open.
Indicators: D_MTR-Cable is displayed. Warning relay opens.
Cleared by: The Dual Servo Motor Power cable short or open corrected.
D MTR Short:
Cause: The Dual Servo Motor has a short.
Indicators: D_MTR-Short is displayed. Warning relay opens.
Cleared by: The Dual Servo Motor has been replaced.
Accumulator Servo Faults:
ASrv Fault:
Cause: Fault line from Accumulator Servo Motor Drive indicating fault state.
Indicator: Warning relay opens Display: AServoFlt.
Cleared by: CPU to issue driver reset immediately.
Option Feature: Turned on only when a Secondary Servo Booster motor is present when running system configuration in Setup
Mode and it is configured to be an “Accumulator”.
ASrvReset:
Cause: The Accumulator Servo Motor drive has detected a problem and asserted Drive Fault.
Indicators: ASrvReset is displayed. Warning relay opens.
Cleared by: End of Reset Signal generation by CPU
AMTRTemp:
Cause: The Accumulator Servo motor is over temperature.
Indicators: DMTRTemp is displayed. Warning relay opens.
Cleared by: The Accumulator Servo Motor has returned to normal temperature.
AResCable:
Cause: The Accumulator Servo Motor Resolver cable has a short or an open.
Indicators: AResCable is displayed. Warning relay opens.
Cleared by: The Accumulator Servo Motor Resolver cable short or open corrected.
A DRV Temp:
Cause: The Accumulator Servo Motor Driver is over temperature.
Indicators: A_DRV_Temp is displayed. Warning relay opens.
Cleared by: The Accumulator Servo Motor Driver has returned to normal temperature.

F. Errors and Error Displays

 F-7 F. Errors and Error Displays

A Replc DRV:
Cause: The Accumulator Servo Motor Driver has a shorted output.
Indicators: A_Replc_DRV is displayed. Warning relay opens.
Cleared by: The Accumulator Servo Motor Driver has been replaced.
A MTR Cable:
Cause: The Accumulator Servo Motor Power cable has a short or an open.
Indicators: A_MTR-Cable is displayed. Warning relay opens.
Cleared by: The Accumulator Servo Motor Power cable short or open corrected.
A MTR Short:
Cause: The Accumulator Servo Motor has a short.
Indicators: A_MTR-Short is displayed. Warning relay opens.
Cleared by: The Accumulator Servo Motor has been replaced.
Servo Primary Booster Faults:
SBstFlt:
Cause: The Primary Servo Booster Drive has detected a problem.
Indicators: Warning relay opens. SBstFlt is displayed. The actuator will continue operation with Primary Servo Motor, with reduced
stroke time.
Cleared by: CPU will attempt to clear Drv fault error until fault condition is corrected.
SBstRest:
Cause: The Servo Booster Motor drive has detected a problem and asserted Drive Fault.
Indicators: SBsteset is displayed. Warning relay opens.
Cleared by: End of Reset Signal generation by CPU
SBstMTRTemp:
Cause: The Servo Booster Motor is over temperature.
Indicators: SBstMTRTemp is displayed. Warning relay opens.
Cleared by: The Servo Booster Motor has returned to normal temperature.
SBstResCable:
Cause: The Servo Booster Motor Resolver cable has a short or an open.
Indicators: SBstResCable is displayed. Warning relay opens.
Cleared by: The Servo Booster Motor Resolver cable short or open corrected.
SBstDRV Temp:
Cause: The Servo Booster Motor Driver is over temperature.
Indicators: SBstDRV_Temp is displayed. Warning relay opens.
Cleared by: The Servo Booster Motor Driver has returned to normal temperature.
SBstReplc DRV:
Cause: The Servo Booster Motor Driver has a shorted output.
Indicators: SBstReplc_DRV is displayed. Warning relay opens.
Cleared by: The Servo Booster Motor Driver has been replaced.

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 F-8

SBstMTR Cable:
Cause: The Servo Booster Motor Power cable has a short or an open.
Indicators: SBstMTR-Cable is displayed. Warning relay opens.
Cleared by: The Servo Booster Motor Power cable short or open corrected.
SBstMTR Short:
Cause: The Servo Booster Motor has a short.
Indicators: SBstMTR-Short is displayed. Warning relay opens.
Cleared by: The Servo Booster Motor has been replaced.
Dual Servo Booster Faults:
DSBstFlt:
Cause: The Dual Booster Servo Motor drive has detected a problem.
Indicators: Warning relay opens. DSBstFlt is displayed. The actuator will continue operation with Primary Servo Motor, with reduced
stroke time.
Cleared by: CPU will attempt to clear Dual Servo Booster fault error until fault condition is corrected.
DSBstReset:
Cause: The Dual Servo Booster Motor drive has detected a problem and asserted Drive Fault.
Indicators: DBstReset is displayed. Warning relay opens.
Cleared by: End of Reset Signal generation by CPU. No RS232 Error Codes for Dual Booster (only 2 connections available).
Primary Induction Drive Faults:
PInducFlt:
Cause: Primary Induction Motor Drive has detected a problem.
Indicators: Warning relay opens. PInducFlt is displayed The actuator may or may not continue normal operation depending on
actuator construction.
Cleared by: CPU will attempt to clear the Primary Induction Drive fault error until fault condition is corrected.
PIndReset:
Cause: The Primary Induction Booster Motor drive has detected a problem and asserted Drive Fault.
Indicators: PIndReset is displayed. Warning relay opens.
Cleared by: End of Reset Signal generation by CPU
Induction Booster Drive Faults:
IBstFlt:
Cause: Induction Booster Motor Drive has detected a problem.
Indicators: Warning relay opens. IBstFlt. Is displayed. The actuator may or may not continue normal operation depending on
actuator construction.
Cleared by: CPU will attempt to clear Induction Booster Drive fault error until fault condition is corrected.
IBstReset:
Cause: The Induction Booster Motor drive has detected a problem and asserted Drive Fault.
Indicators: IBstReset is displayed. Warning relay opens.
Cleared by: End of Reset Signal generation by CPU

F. Errors and Error Displays

 F-9 F. Errors and Error Displays

Primary Stepper Drive Faults:

PStpFlt:
Cause: At least one motor drive has detected a problem.
Indicators: Warning relay opens. PStpFlt is displayed. The actuator may or may not continue normal operation depending on
actuator construction.
Cleared by: CPU will attempt to clear PStpFlt error until fault condition is corrected.
PStpReset:
Cause: The primary stepper motor drive has detected a problem.
Indicators: PStpReset is displayed. Warning relay opens.
Cleared by: End of reset signal generation by CPU.
Dual Stepper Drive Faults:
DStpFlt:
Cause: At least one motor drive has detected a problem.
Indicators: Warning relay opens. DStpFlt The actuator may or may not continue normal operation depending on actuator construction.
Cleared by: CPU will attempt to clear DStpFlt error until fault condition is corrected.
DStpReset:
End of Reset Signal generation by CPU
Accumulator Stepper Drive Faults:
AStpFlt:
Cause: At least one motor drive has detected a problem.
Indicators: Warning relay opens. AStpFlt is displayed. The actuator may or may not continue normal operation depending on
actuator construction.
Cleared by: CPU will attempt to clear AStpFlt error until fault condition is corrected.
AStpReset:
End of Reset Signal generation by CPU

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Xpac Series 3 - Installation and Operation Manual - 9/22 G-1

G. Surge Control Option

G.1 Theory of Operation

High speed operation in one direction during upset conditions can best be handled with REXA’s Surge Control Option. This option
gives the actuator the ability for fast operation in one direction. During normal movements actuator stroking speed is determined
by Power Module speed capabilities. To obtain this second surge speed a coil spring drives the actuator when a solenoid valve
opens. Four additional components are added to the standard actuator:
Mechanical Spring - provides the force to move the actuator in the surge direction.
Solenoid Bypass Valve - bypasses the actuator’s normal hydraulic circuit.
Solid State Relay - interfaces the CPU with the solenoid.
Needle Valve - allows adjustment in Surge Control speed

The CPU will deenergize/energize the solenoid through the electronic relay to allow controlled high speed motion in the spring
direction. Control of this feature is accomplished with the Surge Breakpoint (SG) parameter in the Setup menu.

If the change in control signal is less than the Surge Breakpoint, the actuator operates normally. If the change in control signal is greater than
the Surge Breakpoint (and in the surge motion direction), then the solenoid opens and the actuator is driven by the spring to the new position.

If the actuator is overshooting during a surge event, the Surge Offpt parameter can be used to eliminate this overshoot. Reference
the Drive Menu section in Modes of Operation & Control Parameters in the IOM for additional information regarding setting the
Surge Offpt parameter. Increasing this Surge Offpt parameter will reduce the overshoot until the unit begins to slow down too
much prior to hitting its target position. Figure G.1-1 illustrates the overshoot from a surge event. Increasing the Surge Offpt would
be required to eliminate this issue. Figure G.1-2 shows the expected results when the Surge Offpt parameter is tuned properly.
Figure G.1-3 shows an undershoot condition. Decreasing the Surge Offpt percentage will reduce the undershoot.

Various configurations of the spring package may have been provided. The spring may be installed to open or close the driven
device. Fail-safe position can either be lock in place or in the surge direction.

Figure G.1-1 Overshoot Figure G.1-2 Target position Figure G.1-3 Undershoot
G.2 Installation
The fast response solenoid is a 3-way configuration and piped external to the hydraulic cylinder. An adjustable needle valve is in
line with the solenoid to allow custom adjustment of the surge speed to meet a particular installation. The wires used for the surge
solenoid are a pair of blue wires in the module cable. Refer to certified electrical drawing for wiring details.

G.3 Calibration
Refer to the Control & DRIVES menu for additional information.

G. Surge Control Option

 H-1 H. Build Numbers

H. Build Numbers

The build number is a catalog number REXA uses to designate in complete detail the construction of the actuator. From this number
all configurations can be defined. There are two different categories of build numbers; one is for the mechanical sub-assembly,
and the second is for 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.

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Xpac Series 3 - Installation and Operation Manual - 9/22 H-2

Linear Series Actuator

1 Actuator Type 4 Power Module Size 10 Cable Connection 18 Oil

C= Commercial Linear Cylinder B= B Module S= Terminal Strip (Std.) C= Cold Temp Oil
C= C Module T= Quick Release Connectors F= Biodegradable Oil
L= REXA Block Cylinder
M= 2C Module
P= Power Module Only 11,12 Mechanical Switches O= O2 Service (Krytox)
D= D Module
2 Output A= 2 Switches-SPDT 4X S= Castrol Edge 5W-50
F= 1/2 D Module
O= Dual 1/2 D Module C= 2 Switches-SPDT Class 1, Div 2 19 Special Cylinder
C= 2,000 lbs
G= 2D Module D= Oil Level Switch & 2SPDT Class 1, Div 2 F= Female Threads
D= 4,000 lbs
H= D,P9 Module E= 4 Switches SPDT Class 1, Div 2 G= Sngl Rod End/Nitron 50 Chrome Pit
E= 5,000 lbs
U= D,P20 Module F= Oil Level & 4SPDT Class 1, Div 2 R= 17-4 Plated Chrome Shaft
F= 10,000 lbs I= D,P40 Module G= 2 Switches DPDT Class 1, Div 2 S= Standard Cylinder
G= 15,000 lbs Z= Special
H= Oil Level & 2DPDT Class 1, Div 2 T= 316 SS Plated Chrome Shaft
H= 20,000 lbs 5 Fail Safe Mode/Surge Method
J= 4 Switches DPDT Class 1, Div 2 U= Complete 316SS Cylinder
P= Fail in Place (Std.)
I= 30,000 lbs K= Oil Level Switch & 4DPDT Class 1, Div 2
E= Fail Extend Low Spring V= Nitronics 50 Plated Chrome Shaft
J= 40,000 lbs R= Fail Retract Low Spring Load N= No Switches W= 316SS Cyl w/ Nitronics 50 PC Shaft
K= 80,000 lbs H= Fail Extend High Spring Load O= Oil Level Switch
20 PST Trigger
L= 120,000lbs B= Fail Retract High Spring 13 Area Approvals A= Accumulator Solenoid
A= Accumulator Extend A= ATEX Sone 1, CE
M= 60,000 lbs E= External PST Solenoid
M= Accumulator Retract
X= N/A B= IECEx Zone 2
D= Hydraulic Solenoid Bypass N= None
3 Actuator Stroke/Rotation C= CSA Class 1, Div 1
X= N/A S= Internal PST Solenoid
6 Fail Mode Speed D= NEMA 4X CSA Class 1, Div 1, Tnemec
A= 0.75” U= Fail Safe Solenoid
H= High Speed Soleoid E= CSA Class 1, Div 1
B= 2” 21 Advanced Sensors
N= N/A (Std.) F= SIL General
C= 4” B= Redundant Feedback
S= Standard Solenoid G= NEMA 4X Class 1, Div 1, Tnemec
D= 6” T= WF1 High Speed Solenoid- NO C= Non-Contact & Diff Press
H= SIL, CSA Class 1, Div 1
E= 8” U= WF1 High Speed Solenoid- NC D= Contact Pot & Diff Press
I= SIL, CSA Class 1, Div 1
F= 11” 7 Heater/Solenoid Voltage E= Non-Contact Pot
M= CE, General Locations
A= 115 Volts AC R= Contact Potentiometer
M= 12” N= ATEX ZONE 2, CE
B= 230 Volts AC
G= 16” P= IECEx Zone 1
22 Accumulator Rating
H= 115 VAC/24 VDC
A= ASME Marked Accumulator
H= 22” I= 230 VAC/24 VDC S= General Locations (Std.)
J= No Heater/115 Volts AC T= NEMA 4X, Tnemec C= CE Marked Accumulator
I= 28”
K= No Heater/230 Volts AC 14 Output Limit/Protection N= None
J= 36”
N= No Heater
C= 37%-73% Total Output 23 Corrosion Protection
K= 42” 8 Temp. Rating and Stem Boot
D= 74%-99% Total Output A= AC-15 Accum. Bottles
L= 48” B= Standard Temp With Stem Boot
E= 100%-140% Total Output (Std.) S= Standard
N= 30” H= High Temp Rating
L= Std. Temp Rem. Feedback w/ Stem Boot N= NONE 24 Open
O= 54”
N= NEPCI- No Gauges w/ Stem Boot 15 Design N= None (Std.)
V= 60” 25, 26 Specials
R= Standard Temp Remote Feedback X= X3
P= 66” S= Standard Temp Rating (Std.) A= Design 1
16 On/Off Module
W= 72” T= High Temp w/ Linear Stem Boot B= Design 2
N= None
Q= 84” 9 Manual Override
17 Accumulator Recharge Motor Z= Special
C= Manual Pump & Handwheel
Y= 96”
H= Handwheel/Drill Drive C= 0.3 C-Module 27 Revision
U= 120” N= None (Std.) D= D Module A= Design 1
Z= Special P= Manual Hand Pump N= None Z= Special

H. Build Numbers
 H-3 H. Build Numbers

Rotary/Drive Series Actuator

1 Actuator Type 5 Fail Safe Mode/Surge Method 11,12 Mechanical Switches 18 Oil
D= Drive Units P= Fail in Place (Std.) A= 2 Switches-SPDT 4X C= Cold Temp Oil
E= Fail Extend Low Spring C= 2 Switches-SPDT Class 1, Div 2 F= Biodegradable Oil
R= Rotary Cylinders
R= Fail Retract Low Spring Load D= Oil Level Switch & 2SPDT Class 1, Div 2 O= O2 Service (Krytox)
2 Output
H= Fail Extend High Spring Load E= 4 Switches SPDT Class 1, Div 2 S= Castrol Edge 5W-50
C= 2,500 in*lbs 19 Special Cylinder
B= Fail Retract High Spring F= Oil Level & 4SPDT Class 1, Div 2
D= 5,000 in*lbs F= Female Threads
A= Accumulator Extend G= 2 Switches DPDT Class 1, Div 2
E= 10,000 in*lbs G= Sngl Rod End/Nitron 50 Chrome Pit
M= Accumulator Retract H= Oil Level & 2DPDT Class 1, Div 2
F= 20,000 in*lbs R= 17-4 Plated Chrome Shaft
D= Hydraulic Solenoid Bypass J= 4 Switches DPDT Class 1, Div 2
S= Standard Cylinder
G= 50,000 in*lbs X= N/A K= Oil Level Switch & 4DPDT Class 1, Div 2
T= 316 SS Plated Chrome Shaft
H= 100,00 in*lbs 6 Fail Mode Speed N= No Switches
U= Complete 316SS Cylinder
I= 200,000 in*lbs H= High Speed Soleoid O= Oil Level Switch
V= Nitronics 50 Plated Chrome Shaft
J= 400,000 in*lbs N= N/A (Std.) 13 Area Approvals
W= 316SS Cyl w/ Nitronics 50 PC Shaft
S= Standard Solenoid A= ATEX Sone 1, CE
K= 566,000 in*lbs 20 PST Trigger
T= WF1 High Speed Solenoid- NO B= IECEx Zone 2 A= Accumulator Solenoid
L= 300,000 in*lbs
U= WF1 High Speed Solenoid- NC C= CSA Class 1, Div 1 E= External PST Solenoid
M= 30,000 in*lbs
7 Heater/Solenoid Voltage D= NEMA 4X CSA Class 1, Div 1, Tnemec N= None
Z= Special A= 115 Volts AC E= CSA Class 1, Div 1 S= Internal PST Solenoid
3 Actuator Stroke/Rotation B= 230 Volts AC F= SIL General U= Fail Safe Solenoid
A= 90 Degrees (Std.) H= 115 VAC/24 VDC G= NEMA 4X Class 1, Div 1, Tnemec 21 Advanced Sensors
B= 180 Degrees I= 230 VAC/24 VDC H= SIL, CSA Class 1, Div 1 B= Redundant Feedback
C= 270 Degrees J= No Heater/115 Volts AC I= SIL, CSA Class 1, Div 1 C= Non-Contact & Diff Press
K= No Heater/230 Volts AC M= CE, General Locations D= Contact Pot & Diff Press
D= 280 Degrees
N= No Heater N= ATEX ZONE 2, CE E= Non-Contact Pot
E= 120 Degrees
8 Temp. Rating and Stem Boot P= IECEx Zone 1 R= Contact Potentiometer
I= 320 Degrees 22 Accumulator Rating
B= Standard Temp With Stem Boot S= General Locations (Std.)
J= 350 Degrees A= ASME Marked Accumulator
H= High Temp Rating T= NEMA 4X, Tnemec
4 Power Module Size L= Std. Temp Rem. Feedback w/ Stem Boot 14 Output Limit/Protection
C= CE Marked Accumulator

B= B Module N= None
N= NEPCI- No Gauges w/ Stem Boot C= 37%-73% Total Output
23 Corrosion Protection
C= C Module R= Standard Temp Remote Feedback D= 74%-99% Total Output
A= AC-15 Accum. Bottles
M= 2C Module S= Standard Temp Rating (Std.) E= 100%-140% Total Output (Std.)
S= Standard
D= D Module T= High Temp w/ Linear Stem Boot N= NONE
24 Open
F= 1/2 D Module
9 Manual Override 15 Design N= None (Std.)
C= Manual Pump & Handwheel X= X3 25, 26 Specials
O= Dual 1/2 D Module
H= Handwheel/Drill Drive 16 On/Off Module A= Design 1
G= 2D Module
N= None (Std.) N= None B= Design 2
H= D,P9 Module
P= Manual Hand Pump 17 Accumulator Recharge Motor Z= Special
U= D,P20 Module 10 Cable Connection C= 0.3 C-Module 27 Revision
I= D,P40 Module S= Terminal Strip (Std.) D= D Module A= Design 1
Z= Special T= Quick Release Connectors N= None Z= Special

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Xpac Series 3 - Installation and Operation Manual - 9/22 H-4

Electronic Control Enclosure

1 Power Module Size 4 Area Approvals 11, 12 Software 22 Switches

B= B Module S= General Locations (Std.) A= Standard Software (Std.) N= Linear Act. None
C= C Module C= CSA Class 1, Div 2 (B,C,D) 13 Electronics Supplied
T= Linear Act. Two Switches
D= D Module Y= Yes
E= CSA Class 1, Div 1 G= Linear Act. 2 DPDT
F= ½D Module 14 Cable Termination
N= Atex/CE Zone 2 R= Rotary Act. None
G= 2D Module T= Quick Connect Cables
5 Enclosure Material P= Rotary Act. Two Switches
H= D-P9 Module F= Quick Release Actuator End Only
T= 316 Stainless Steel, NEMA 4X (Std.) X= Rotary Act. Four Switches
I= D-P40 Module D= Din Rail
P= Painted Steel, NEMA 4 (Std. X2)
M= 2C Xpac Module
15 Design A= Linear Act. None w/ Low Oil
6 Controls X= X3
2 Power Supply B= Linear Act. Two w/ Low Oil
E= External (Std.) 16 On/Off Module
A= 120 VAC C= Linear Act. Four w/ Low Oil
I= Internal N= None
B= 240/208 VAC D= Rotary Act. None w/ Low Oil
C= Int Controls w/ Ext Buttons/Window 17 Accumulator Recharge Motor
C= 480 VAC E= Rotary Act. Two w/ Low Oil
Z= Special N= None
H= 415 VAC 1–Phase
F= Rotary Act. Four w/ Low Oil
C= R1-C Module
I= 240 VAC 3–Phase 7 Remote Manual Station
18 Seating Control H= Linear Act. Four
J= 480 VAC 3–Phase A= Basic Station
N= None 23 Trip Signal
K= 380 VAC 3–Phase B= Basic Station with Display
S= Solenoid seat N= None
L= 600 VAC 3–Phase C= Remote Station Compatibility
L= Seat load cylinder
A= Loss of power only
M= 240 Volts Module w/o transfer N= None (Std.) 19 Wireless
N= 600 VAC 1-Phase B= 24-120 Trip signal only
8 Actuator Temperature Rating N= No Wireless Transmitter
O= 380 VAC 1-Phase C= 24 VDC- Customer Power Solenoids
S= Standard 200 °F (93 °C) Temp Rating B= Bluetooth Diagnostics
T= 400 VAC 3-Phase D= 120 VDC- Customer Power Solenoids
H= High 250 °F (121 °C) Temp Rating 20 PST-Trigger
P= 575, 3-Phase E= Dry Contact
R= Remote Feedback Std. 200 °F (93 °C) N= No PST
U= 208 Ctl. & Servo/480 Ind. Boost, 3 ph.
M= High Temp Rating, Rotary or Drive
C= No Contact Input 24 Environmental Protection
V= 240 VAC 1-Ph, Xfrmr 1/2D 120V T= Contact Input
9 Position Transmitter N= None (Std.)
S= 200 VAC, 1-Phase L= Local Button
A= Active 4–20 mA C= Conformal Coating
3 Control Signal T= Local and Contact
P= Passive 4–20 mA (Std.) 25, 26 Specials
G= Analog 4-20 mA w/ Surge Sup. (Std.) 21 Advanced Sensors
10 Solenoid Control N= None
T= Two Position - 1 Signal N= None (Std.)
M= Manual - 2 Signal N= None (Std.) 27 Revision
C= Output monitoring
J= Hart 4–20 mA w/ Surge Sup. A= Accumulator System D= Contact Pot & Analog Diff Pressure A= Design 1

Z= Special S= Spring Surge Option E= Non-Contact Z= Special

H. Build Numbers
 H-5 H. Build Numbers

Mounting Systems
Linear Series Mouning

1 Actuator Type 3 Actuator Stroke 5 Certified Drawings 7 Variations

N= No Mounting Hardware A= .75” (.02 m)
A= Actuator Outline N= No Factory Mount & Calibrate
L= REXA Block Cylinder B= 2” (.05 m)
C= 4” (.10 m) C= Control Enclosure Outline A= L2 000 Mount & Calibrate
C= Commercial Linear Cylinder
D= 6” (.15 m) E= Electrical Interconnect Schematic
2 Output B= L4K-L10K Mount & Calibrate
E= 8” (.20 m)
C= 2,000 lbf (8,896 N) O= Actuator & Interconnect
F= 11” (.28 m) C= L15K & Up, Mount & Calibrate
D= 4,000 lbf (17,793 N) G= 16” (.40 m) D= Actuator & Enclosure & Interconnect
E= 5,000 lbf (22,241 N) H= 22” (.56 m) 8 Inspection Level
N= No Certified Drawings
F= 10,000 lbf (44,482 N) I= 28” (.71 m)
S= Standard Inspection
G= 15,000 lbf (66,723 N) J= 36” (.91 m) 6 Other Documentation
H= 20,000 lbf (88,964 N) K= 42” (1.07 m) A= Advanced Inspection (Level II)
B= Bill of Materials
I= 30,000 lbf (133,447 N) L= 48” (1.22 m)
P= Premium Inspection (Level I)
J= 40,000 lbf (177,929 N) Z= Special C= Certificate of Conformance
M= 60,000 lbf (266,893 N) 4 Valve Attachment 9 Packaging
F= Final Inspection Report
K= 80,000 lbf (355,858 N) S= Down Seat Split Clamp
A= All (BOM, COC & FIR) D= Domestic (Std.)
L= 120,000 lbf (533,787 N) B= Up Seat Split Clamp
Z= Special N= No Clamp N= No Other Documentation E= Export

Rotary Series Mounting

1 Actuator Type 3 Actuator Rotation 5 Certified Drawings 7 Variations

N= No Mounting Hardware A= 90 Degrees (Std.) A= Actuator Outline N= No Factory Mount & Calibrate
R= Rotary Cylinder B= 180 Degrees C= Control Enclosure Outline A= Factory Mount & Cal 4” or Less
C= 270 Degrees E= Electrical Interconnect Schematic B= Factory Mount & Cal 6” to 10”
2 Output D= 280 Degrees O= Actuator & Interconnect C= Factory Mount & Cal 12” to 14”
C= 2,500 lb·in (282 N·m) E= 120 Degrees
D= Actuator & Enclosure & Interconnect D= Factory Mount & Cal Over 16”
D= 5,000 lb·in (565 N·m) Z= Special
N= No Certified Drawings 8 Inspection Level
E= 10,000 lb·in (1,130 N·m)
4 Valve Attachment S= Standard Inspection
F= 20,000 lb·in (2,260 N·m) 6 Other Documentation
N= No Mounting Hardware
G= 50,000 lb·in (5,650 N·m) B= Bill of Materials A= Advanced Inspection (Level II)
A= 4” or less
H= 100,000 lb·in (11,300 N·m) C= Certificate of Conformance P= Premium Inspection (Level I)
B= 6” to 10”
I= 200,000 lb·in (22,597 N·m) C= 12” to 14” F= Final Inspection Report 9 Packaging
J= 400,000 lb·in (45 194 N·m) D= 16” to 20” A= All (BOM, COC & FIR) D= Domestic (Std.)
Z= Special E= 20” and up N= No Other Documentation E= Export

The most common codes are shown above. However, the Xpac 3 is an engineered product and REXA practices a policy of continuous
improvement. As such, additional codes may be available or may be added without notice. Please contact the factory for information on
any code not shown above.

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Xpac Series 3 - Installation and Operation Manual - 9/22 H-6

Drive Series Mounting

1 Actuator Type 3 Actuator Rotation 5 Certified Drawings 7 Variations

D= Drive Unit A= 90 Degrees (Std.) A= Actuator Outline N= No Linkage Kit
B= 180 Degrees C= Control Enclosure Outline
2 Output C= Custom Linkage Kit
C= 270 Degrees E= Electrical Interconnect Schematic
C= 2,500 lb·in (282 N·m)
O= Actuator & Interconnect 8 Inspection Level
D= 280 Degrees
D= 5,000 lb·in (565 N·m) D= Actuator & Enclosure & Interconnect
E= 120 Degrees S= Standard Inspection
E= 10,000 lb·in (1,130 N·m) N= No Certified Drawings
Z= Special A= Advanced Inspection (Level II)
F= 20,000 lb·in (2,260 N·m)
6 Other Documentation
G= 50,000 lb·in (5,650 N·m) 4 Valve Attachment P= Premium Inspection (Level I)
B= Bill of Materials
H= 100,000 lb·in (11,300 N·m) S= Standard Base & Arm C= Certificate of Conformance
9 Packaging
I= 200,000 lb·in (22,597 N·m) A= Standard Base & Custom Arm F= Final Inspection Report
J= 400,000 lb·in (45,194 N·m) B= Custom Base & Standard Arm A= All (BOM, COC & FIR) D= Domestic (Std.)

Z= Special C= Custom Base & Custom Arm N= No Other Documentation E= Export

Linear Fisher Mounting

1 Actuator Type 5 Certified Drawings 8 Seat Loading Method 13 Stem Thread

N= No Mounting Hardware A= Actuator Outline N= None (Std.) B=  3/8” –24
L= REXA Block Cylinder C= Control Enclosure Outline S= Seat Load Cylinder D=  ½” –20
C= Commercial Linear Cylinder C= Elastic Coupling Extend
E= Electrical Interconnect Schematic F=  ¾” –16
2 Output O= Actuator & Interconnect
U= Elastic Coupling Retract
H=  1” –14
C= 2,000 lbf (8,896 N) Z= Special
D= Actuator & Enclosure & Interconnect I=  1-¼” –12
D= 4,000 lbf (17,793 N)
N= No Certified Drawings 9 Mount & Cal
E= 5,000 lbf (22,241 N) 14 Stem Height
N= No Factory Mount & Calibrate
F= 10,000 lbf (44,482 N) 6 Other Documentation A=  4-¾”
A= L2 000 Mount & Calibrate
G= 15,000 lbf (66,723 N) B= Bill of Materials
B= L4K-L10K Mount & Calibrate B=  6-3/16”
H= 20,000 lbf (88,964 N)
C= Certificate of Conformance C= L15K & Up, Mount & Calibrate C=  6-5/8”
Z= Special
F= Final Inspection Report D=  8-7/8”
3 Actuator Stroke 10 Inspection Level
A= All (BOM, COC & FIR) E=  9-5/8”
A= .75” (.02 m) S= Standard Inspection
N= No Other Documentation
B= 2” (.05 m) A= Advanced Inspection (Level II) 15 Valve Stroke
C= 4” (.10 m) 7 Fail Safe Mode P= Premium Inspection (Level I) A=  ¼” to 1”
D= 6” (.15 m) P= Fail In Place (Std.) 11 Packaging B=  1-1/8” to 1-7/8”
E= 8” (.20 m)
E= Fail Extend Low Spring Load D= Domestic (Std.) H=  2” and up
F= 11” (.28 m)
R= Fail Retract Low Spring Load E= Export
G= 16” (.40 m) Z=  Special
H= Fail Extend High Spring Load
Z= Special 12 Yoke Boss
16 Variations
B= Fail Retract High Spring Load A= 2-1/8”
4 Valve Attachment N= None
S= Down Seat Split Clamp A= Accumulator Extend C= 2-3/16”
B= Up Seat Split Clamp M= Accumulator Retract E= 3-9/16” 17 Revision
N= No Clamp Z= Special G= 5” A= Current Rev

H. Build Numbers
 M-1 M. Manual Operators

M. Manual Operators

The Xpac has two types of manual operators available: Declutchable Handwheel / Drill Drive and Manual Hydraulic Pump. Since
both options utilize our hydraulic circuit for override operation, they will only function if the system is in working order.

CAUTION: Before attempting to operate any manual override feature, make sure that the electric power is OFF.

M.1 Declutchable Handwheel

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

Handwheel Revolutions
Power Module B C, ½D D
Linear (To move one inch per 1 000 lb of rated thrust) ~75 ~25 ~13
Rotary (90° of rotation/1 000 lb·in of rated torque) ~200 ~65 ~33

Figure M.1-1 Handwheel Assembly Figure M.1-2 Drill Drive Figure M.1-3 Drill Drive with Drill
M.1.2 Declutchable Drill Drive

The drill drive is part of the handwheel assembly that can be used on standard B, C, 1/2D, and D power modules rated for hazardous
but non-explosion proof environments to drive the unit. The handwheel can be removed by simply pulling on it to expose a 5/16”
hex drive. To operate, connect an appropriate drill to the 5/16” hex. Push the drive in and turn. One half-revolution may be required
before proper engagement, since the drive must contact a slot on the end of the motor shaft. Clockwise rotation of the manual
operator will retract the stem on a linear unit and rotate the shaft clockwise (looking at the feedback housing) on a rotary unit. The
drive will declutch by moving outwards when released.

Note: The actuator’s drive train and cylinder must be in proper working order to operate handwheel/drill drive.

CAUTION: Care must be taken to ensure the drill gun is limited to 2 000 rpm. Running into a mechanical stop using a
drill may damage the actuator and potentially the equipment it is attached to. As the actuator nears the end point,
decrease drill speed so damage doesn’t occur.

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 M-2

M.2 Manual Hydraulic Pump

The manual hydraulic pump can be installed on all units and needs only the cylinder side of the hydraulic circuit and the FMV check
valves to be in working order. If the gear pump or suction check valves fail, the manual hydraulic pump will still provide a means
for manual operation.

To operate the manual hydraulic pump, insert lever into the piston assembly and pump the handle up and down. To reverse the
actuator direction, either push in or pull out the black, direction control knob located on the bottom of the assembly.

Note: It is not advisable to leave the lever in the piston assembly when the hydraulic pump is not in use.

Directional control knob

Figure M.2 Manual Hydraulic Pump

Manual Hydraulic Pump Speeds (# Of Pumps)
Linear (To move one inch/1 000 lb of rated thrust) ~1
Rotary (90º of rotation/1000 lb·in of rated torque) ~2.5

M.3 Fail-Safe Unit Operation

Fail-safe units, Spring Return and Accumulator, utilize solenoid valves in the fail-safe operation. Upon loss of power these solenoids
will change state. Generation 1 High Speed Solenoid

In order for manual operation, solenoids must be in position B for normally open solenoids. Manually override them so they appear
as shown in Figure M.3.

Figure M.3 Generation 1 Solenoid Manual Override Levers (Position B)

M. Manual Operators
 M-3 M. Manual Operators

M.3.1 Generation 2 High Speed Solenoid

To manually override the second generation of high speed solenoids follow the below steps.

1. Remove the cover of the solenoid.

2. Turn the jam nut counter clockwise to loosen.

3. Turn the needle valve adjustment knob clockwise to close. This will keep the solenoid valve closed without power and will allow
use of the manual hydraulic pump.

*Note: Count and record how many turns are needed to fully turn the needle valve adjustment knob clockwise to close. This quantity
will be used to reset the needle valve adjustment knob to the same position, retaining its factory-set trip speed as specified by the
customer.

WARNING: After using the handwheel, the overrides must be returned to their open position or the unit will not
operate correctly when power is restored or trip signal removed. If only one override is returned to the open position
after a trip, damage to the power module may occur. Changing the override(s) back may also cause the actuator to
run to the fail-safe position.

Refer to Rotary Spring Fail and Linear Spring Fail sections under Mechanical Installation for additional information.

Jam
Adjustment nut
Knob

Figure M.3.1 Generation 2 Solenoid

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 N-1

HART® Field Device Setup and Specification

Table of Contents
1. DEVICE IDENTIFICATION AND CAPABILITY ����������������������������������������������������������������������������������������������������������������������������������������������������������������������N-2
1.1 Capability Checklist ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������N-2
2. TERMS & DEFINITIONS ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������N-2
3. PRODUCT SCOPE ����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������N-3
4. PRODUCT INTERFACES �����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������N-3
4.1. Host interface ����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������N-3
4.2. Install/Update REXA DD ��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������N-3
4.3. Setup Device Polling Address Search Range �����������������������������������������������������������������������������������������������������������������������������������������������������N-5
4.4. Connect to the Actuator �������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������N-5
4.5. Device Online Menu ���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������N-7
4.6. Device Settings �������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������N-7
4.7. Monitor X3 Device’s Operation Process ���������������������������������������������������������������������������������������������������������������������������������������������������������������N-9
4.8. Get X3 Device Diagnostic Information ����������������������������������������������������������������������������������������������������������������������������������������������������������������N-9
5. POSSIBLE TROUBLE SHOOTING METHODS ������������������������������������������������������������������������������������������������������������������������������������������������������������������ N-11
5.1. HART Secondary Master Device �������������������������������������������������������������������������������������������������������������������������������������������������������������������������� N-11
6. DYNAMIC VARIABLES ����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� N-11
6.1. Control Signal ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� N-11
6.2. Position ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� N-11
6.3. Torque/ Thrust ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ N-11
6.4. Accumulator ��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� N-11
7. STATUS INFORMATION ��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� N-11
7.1. Device Status �������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� N-11
7.2. Extended Device Status ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ N-11
7.3. Additional Device Status (Command #48) ������������������������������������������������������������������������������������������������������������������������������������������������������ N-11
8. UNIVERSAL COMMANDS ���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� N-13
9. COMMON PRACTICE COMMANDS ���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� N-14
10. DEVICE-SPECIFIC COMMANDS ��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� N-14
11. TABLES ����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� N-14
11.1. Unit Codes ��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� N-14
12. UNSUPPORTED MODES ���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� N-14
12.1. Burst Mode ��������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� N-14
12.2. Catch Device Variable ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� N-14

N. HART® Field Device Setup and Specification

 N-2 N. HART® Field Device Setup and Specification

1. DEVICE IDENTIFICATION AND CAPABILITY

Manufacturer Name: REXA Model Name(s): X3

Manufacture ID Code: 222 (DE Hex) Device Type Code: 56961(DE81 Hex)

HART Protocol Revision: 7.6 Device Revision: 1

Number of Device Variables: 6

Physical Layers Supported: FSK

Physical Device Category: Actuator

1.1 Capability Checklist

Manufacturer, model and revision REXA, Xpac Series X3
Device type Actuator
HART revision 7.6
Device Description available Yes
Number and type of sensors 2 available from HART
Number and type of actuators Electrohydraulic
Number and type of host side signals 1: 4 - 20mA analog
Number of Device Variables 6
Number of Dynamic Variables 4
Mappable Dynamic Variables? Yes
Number of common-practice commands 3
Number of device-specific commands 53
Bits of additional device status 19
Alternative operating modes? Yes
Burst mode? No
Write-protection? Yes, not in Setup mode

2. TERMS & DEFINITIONS

HART DTM Device Type Manager for HART devices

Device Type Manager (DTM) Software component (device driver) for configuring, diagnosing, forcing,
displaying the measured variables, and so on of a field device. It is compatible
with the device and supplies device-specific documentation.

Highway addressable remote transducer (HART) Digital communication protocol developed for industrial process application.

GUI Graphical Unser Interface

Device Descriptor (DD) Software component (device driver) for configuring, diagnosing, forcing,
displaying the measured variables, and so on of a field device. It is compatible
with the device and supplies device-specific documentation.

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 N-3

3. PRODUCT SCOPE
REXA provides device setup, monitoring and diagnostic information about the actuator through HART technology over the analog
control signal input to the actuator. The analog control signal is the only way to remotely move/control the actuator. The following
functions are supported:
Identification
• Display general actuator information such as actuator model, tag identification, actuator serial number and software/
hardware/HART version information.
Configuration
• View and update the actuator configuration parameters. *
Monitor
• View dynamic variables in real time such as Control Signal, Position, Torque / Thrust and Accumulator Pressure
Status
• View real time status and specific warning or alarm details
Diagnosis
• View the alarm and warning current and historic counters
• Display actuator Start / Stroke counters
Mode
• Display device operational modes such as setup, manual and auto modes.
*Note: No parameters can be written into the actuator unless that actuator is in calibration mode.
4. PRODUCT INTERFACES
4.1. Host interface
Through DD (Device Descriptor) technology, REXA provides users rich menu contents through host HART application. Each host application
PLC, Field Communicator and Asset Management Software application will have its own look, feel and screen navigation however the
content shown in this manual should all be available. Some of host software platform’s utilize iDTM or DTM frame technology to organize
the DD information into their applications format. These systems typically have a built-in translation function however the HOST system
support team will be responsible for handling the DD integration. Rexa does not supply a vendor specific DTM file. This manual shows
examples of numerous host applications to illustrate examples of the functionality, however the host system has final control of the way
in which the information is displayed and controlled on the console screen.

4.2. Install/Update REXA DD

All host HART application have a way to set up a new device onto the network which allows users to install/update/upload device
descriptor “DD” files. The “DD” files consist of two separate files, an “xxxx.fm8” and “xxxx.sym” file. Below is an example screen capture.

N. HART® Field Device Setup and Specification

 N-4 N. HART® Field Device Setup and Specification

There are multiple ways Host programs can handle the integration of a field device (Rexa Actuator).

Basic HART Commands / Generic DTM Option

When a field device is connected to a HART Host and there are no device driver files installed the Host system will communicate
using HART “Universal” and “Common Practice Commands”. The screen shot below provides an example. Variable are listed as “PV” –
Primary variable, “SV” Secondary Variable, “TV” – Tertiary Variable, “QV” Quaternary Variable.

DD & Advanced iDTM Translators

When a field device is connected to a HART Host and there are “DD” files installed the Host system will communicate using device
specific Commands. The screen shots below provides an example of how the information will be presented in a GUI format with the
correct variable labels and units.

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 N-5

Without the use of the DD and iDTM technology formed GUI screens as shown below would just be presented as a data file.

4.3. Setup Device Polling Address Search Range

REXA is configured with the polling address 0 (can be updated as needed to 64).

4.4. Connect to the Actuator

Connect two-wire 4-20mA loop to actuator from a HART compatible HOST card

Picture 1 and 2 illustrate the factory and customer control signal connections.

N. HART® Field Device Setup and Specification

 N-6 N. HART® Field Device Setup and Specification

X3 Interconnect Board

Picture 1 Control Signal Factory Connections

Control Signal Input

4-20mA DC with HART
Communication

Picture 2 Control Signal Customer Connections

It is recommended to use high quality cable meeting the following requirements as a minimum:

Cable Type 1 Pair 24 AWG

Shield Bi-Laminate (Alum+Poly) 100% Coverage
Nom. Conductor DCR 24.1 Ohm/1000ft
UL Voltage Rating 300 V (CMP)
Max Current 2.2 Amps per Conductor at 25 C

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 N-7

4.5. Device Online Menu

**Not available on all models.
Write Protection

Write is only allowed in setup mode. To write a parameter, the value of the parameter needs to be modified and may also need to
be highlighted, and a send or apply button has to be clicked to send its value to the device.

Host HART application allows user to get an overview of the device through online menus or navigation windows provide in the
host application. While the device is Online the parameters are greyed out and can not be modified. In order to modify parameters,
the device must be put into setup Mode.

4.6. Device Settings

Navigate the online menu through host HART application, user can find the device setup menu.

N. HART® Field Device Setup and Specification

 N-8 N. HART® Field Device Setup and Specification

Device Identification Settings can be further opened as follows

At the setup page, the parameters in white is writable while the ones in grey are read-only.

Below are the example of setting commission date:

Before the setting:

After the setting:

To satisfy user’s convenience, REXA treat short tag as a part of the long tag.

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 N-9

4.7. Monitor X3 Device’s Operation Process

Host HART application can monitor X3 device through process variables.

The actuator can be in auto, manual, or setup modes. It is settable through HART command and the front panel.

4.8. Get X3 Device Diagnostic Information

By going to menu diagnostic, user can obtain X3’s diagnostic information.

N. HART® Field Device Setup and Specification

 N-10 N. HART® Field Device Setup and Specification

Further clicking on “Servo Detailed Status” on diagnostics page, user can get Servo Motor Detailed Status information:

Also, by clicking on “Alarm/Warning and Start/Stroke Counters” on the diagnostic page, user can navigate to the counter page:

To get updated counters, user can click on the “Get Counters” button, and further click on “OK” on the question of “Read All The
Counters Now?”

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 N-11

5. POSSIBLE TROUBLE SHOOTING METHODS

5.1. HART Secondary Master Device
Using HART secondary master device, either hand-held like Emerson 475 or Trex, or tablet or
laptop with HART applications to check the HART wiring and communications.

For example, the HART probes of Emerson 475 can be connected to 4-20mA control signal
two wires that are connected to X3 and read X3’s control signal settings through generic DD
as shown below:

6. DYNAMIC VARIABLES
This device uses dynamic variable mapping based on system configurations. In X3 device, the following mapping is typical. When
Torque/Thrust and/or Accumulator are not available, position 2 and/or pressure 2 can be mapped to the dynamic variables. The
position 2 and pressure 2 can be a fixed value used for testing purpose

Dynamic Variable Device Variable Number Name UNIT

PV 0 Control Signal (Setpoint) %
SV 1 Position %
TV 2 **Torque/ Thrust lbf.in/lbf
QV 3 **Accumulator Pressure psi

**Not available on all models.

6.1. Control Signal

4~20mA input signal as the setpoint of the position control. This variable is displayed in percentage.

6.2. Position
This variable is the current position of the actuator and is displayed in percentage of the actuators calibrated span.

6.3. Torque/ Thrust

The actuator differential pressure (close pressure – open pressure) are used for calculating its torque or thrust based on the device’s
model number. A positive value indicated extending/CW and a negative valve indicates retracting/CCW.

6.4. Accumulator
4~20mA accumulator pressure signal represents the pressure from 0 to 3000psi.

7. STATUS INFORMATION
7.1. Device Status
Bit 4 (“More Status Available”) is contained in each communication package being sent from the actuator to the host. This is set to 1
whenever any status bit is detected. Command #48 gives further detail.

7.2. Extended Device Status

Command 48 warning status is the prediction of device maintenance needed. Command 48 alarm status means the variables are
in alert status.

7.3. Additional Device Status (Command #48)

Command #48 returns 19 bytes of status data, with the following status information:

N. HART® Field Device Setup and Specification

 N-12 N. HART® Field Device Setup and Specification

Table 1
Byte Bit Meaning Class Device Status Bits Set
0 0 Primary servo fault Warning 4
1** Dual servo fault Warning 4
2** Accumulator servo fault Warning 4
3** Servo booster fault Warning 4
4 Primary stepper fault Warning 4
5** Dual stepper fault Warning 4
6** Accumulator stepper fault Warning 4
7** Induction boost fault Warning 4
1 0** Dual boost fault Warning 4
1** Primary induction fault Warning 4
2 Main feedback bad Alarm 4, 7
3** Redundant feedback bad Warning 4
4 Control signal failure Alarm 4, 7
5 Stall Alarm 4, 7
6 Direction error Alarm 4, 7
7 15v supply failure Alarm 4, 7
2 0 -5v supply failure Alarm 4, 7
1** Accumulator pressure bad Warning 4
2** Accumulator pressure low Warning 4
3** Output Limit Warning Warning 4
4** Accumulator timeout Warning 4
5** Open pressure bad Warning 4
6** Close pressure bad Warning 4
7** SLC Feedback Bad Alarm 4, 7
3 0** SLC Stop Warning 4
1 AC High Warning 4
2 AC Low Warning 4
3 Clock Battery Low Warning 4
4** Output Limit Alarm Alarm 4, 7
5** Redundant Feedback Offset Warning 4
6 Invalid Hardware Warning 4
7** Invalid PST Warning 4
4 0** PST Time Elapsed Warning 4
6 0 Set whenever warning bit is set Warning
1 Set whenever alarm bit is set Alarm
14 0** Primary servo low voltage Warning 4
1** Primary servo RS232 connection Warning 4
2** Primary servo motor temperature Warning 4
3** Primary servo resolver Warning 4

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 N-13

4** Primary servo drive temperature Warning 4

5** Primary servo high voltage Warning 4
6** Primary servo motor cable Warning 4
7** Primary servo motor short Warning 4
15 0** Primary servo replace drive Warning 4
1** Primary servo drive limit Warning 4
2** Dual servo low voltage Warning 4
3** Dual servo RS232 connection Warning 4
4** Dual servo motor temperature Warning 4
5** Dual servo resolver Warning 4
6** Dual servo drive temperature Warning 4
7** Dual servo high voltage Warning 4
16 0** Dual servo motor cable Warning 4
1** Dual servo motor short Warning 4
2** Dual servo replace drive Warning 4
3** Dual servo drive limit Warning 4
4** Accumulator servo low voltage Warning 4
5** Accumulator servo RS232 connection Warning 4
6** Accumulator servo motor temperature Warning 4
7** Accumulator servo resolver Warning 4
17 0** Accumulator servo drive temperature Warning 4
1** Accumulator servo high voltage Warning 4
2** Accumulator servo motor cable Warning 4
3** Accumulator servo motor short Warning 4
4** Accumulator servo replace drive Warning 4
5** Accumulator servo drive limit Warning 4
6** Booster servo low voltage Warning 4
7** Booster servo RS232 connection Warning 4
18 0** Booster servo motor temperature Warning 4
1** Booster servo resolver Warning 4
2** Booster servo drive temperature Warning 4
3** Booster servo high voltage Warning 4
4** Booster servo motor cable Warning 4
5** Booster servo motor short Warning 4
6** Booster servo replace drive Warning 4
7** Booster servo drive limit Warning 4

**Not available on all models.

These bits are set or cleared by the self-test executed at power up or following a reset command. They are also set (but not cleared)
by any failure detected during continuous background self-testing

8. UNIVERSAL COMMANDS
Universal Commands 0, 1, 2, 3, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 38, 48

N. HART® Field Device Setup and Specification

 N-14 N. HART® Field Device Setup and Specification

9. COMMON PRACTICE COMMANDS

Common Practice Commands 33, 50, 54
10. DEVICE-SPECIFIC COMMANDS
The following device-specific commands are implemented:
Command #131: Read Commission Date, Model Number and Command #172: Read Warning/Alarm Counters Part 3
Serial Number Command #174: Read Warning/Alarm Counters Part 5
Command #132: Read Device Mode and Condition Command #175: Read Warning/Alarm Counters Part 6
Command #133: Read Configurations and Control Parameter Settings Command #176: Read Actuator Start and Stroke Counters
Command #134: Read Accumulator Parameter Settings Command #185: Write Gain
Command #135: Read Output Parameter Settings Command #186: Write Failsafe State
Command #136: Read PST Trigger Command #187: Write Failsafe
Command #137: Read PST Time Command #188: Write Power On
Command #138: Read PST Auto Schedule Command #189: Write Bumpless
Command #139: Read PST Targets Command #190: Write Deadband
Command #140: Read PST Signal Control Command #191: Write Surge On
Command #142: Read Failsafe Command #192: Write Surge
Command #143: Read Cal. Stroke Command #193: Write PST Trigger
Command #144: Read Surge On Command #194: Write PST Targets
Command #145: Read Surge Settings Command #195: Write Delta Pressure Settings
Command #146: Read Speed Breakpoint Command #196: Write Relays
Command #147: Read Low/Down Speed Command #197: Write Booster On
Command #148: Read Speeds Command #198: Write Booster Offpoint
Command #149: Read Min Mod Command #199: Write Accumulator
Command #150: Read Delta Pressure Settings Command #200: Write Two Speed
Command #151: Read Booster On Command #201: Write Maximum High Speed
Command #152: Read Booster Offpoint Command #202: Write Maximum Low Speed
Command #153: Read Calibration Parameters Command #203: Write Speed Breakpoint
Command #154: Read Redundant Calibration Parameters Command #204: Write Device Mode
Command #170: Read Warning/Alarm Counters Part 1 Command #205: Write Commission Date
Command #171: Read Warning/Alarm Counters Part 2
11. TABLES
11.1. Unit Codes
Name Unit Code Unit
Torque Unit 240 lbf.in
Thrust Unit 241 lbf

12. UNSUPPORTED MODES

12.1. Burst Mode
This Field Device does not support Burst Mode.

12.2. Catch Device Variable

This Field Device does not support Catch Device Variable.

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 O-1

O. Output Load Protection

O.1 Theory of Operation

Each Xpac power module is equipped with two pressure limiting cartridges that provide output load protection to the device the
actuator is attached to. These valves are located under the wire cover on the power module body as shown in Figure O.2. The valve
to the left controls the pressure in the extend or clockwise direction.

O.2 Identification
Each valve has a pressure label sticker indicating its range of adjustment. The range corresponds to the spring installed under the
adjustment cap as noted in Table O.2
Table O.2 Adjustment Range
Adjustment Range (psi) 2,250-3,000
Spring Color Brown (Std)
Standard springs are 2,250 – 3,000 psi unless specified otherwise. The limiting cartridge is then factory set to 2,300 – 2,400 psi. To
translate pressure into actuator output, use the following formula:

( )(
Pressure Gauge Reading × Actuator Rated Output = Actual Output
2,000 psi ) [ ]
The pressure gauge reading can be obtained from the corresponding pressure gauge shown in Figure O.2. This value should be the
delta between the two gauges when calculating actual output.

O.3 Adjustment:
• Loosen the lock nut while holding the adjustment cap in place.

• While running the actuator in a hard stop, read the corresponding gauge to the valve that is being adjusted.

• Turn the adjustment cap CW to increase the relief pressure and CCW to decrease the relief pressure.

Note: The adjustment cap does not have a hard stop and will unthread.

• Tighten lock nut against the cap to 100 lb·in (11 N·m) and test
set pressure.

O.4 Spring Change:

• Loosen the lock nut.

• Unthread the adjustment cap.

• Replace the spring.

• Replace the adjustment cap.

• Follow the adjustment procedure (O.3), above.

Figure O.2 Pressure Relief Valve

O. Output Load Protection

 P-1 P. Interconnect Diagrams & Control Enclosure Drawings

P. Control Enclosure Drawings & Interconnect Diagrams

B and C Stepper Enclosure Diagram..............................................................................................................................................P-2

B and C Stepper 115 VAC Wiring Diagram.....................................................................................................................................P-3
B and C Stepper 230 VAC Wiring Diagram.....................................................................................................................................P-4
2C Stepper Enclosure Diagram.......................................................................................................................................................P-5
2C Stepper 115VAC Wiring Diagram..............................................................................................................................................P-6
½D and D Servo Enclosure Diagram..............................................................................................................................................P-7
½ D Servo 115VAC Wiring Diagram...............................................................................................................................................P-8
D Servo 230 VAC Wiring Diagram...................................................................................................................................................P-9
Dual ½D and D Servo Enclosure Diagram...................................................................................................................................P-10
2D Servo 230 VAC Wiring Diagram...............................................................................................................................................P-11
D,P9 Servo 230 VAC Enclosure Diagram......................................................................................................................................P-12
D,P9 Servo 230 VAC Wiring Diagram............................................................................................................................................P-13
D,P20 Servo 230 VAC Enclosure Diagram....................................................................................................................................P-14
D,P20 Servo 230 VAC Wiring Diagram.........................................................................................................................................P-15
D,P40 Servo 230 VAC Enclosure Diagram...................................................................................................................................P- 16
D,P40 Servo 230 VAC Wiring Diagram........................................................................................................................................P- 17

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 P-2

B and C Stepper Enclosure Diagram

STANDARDS
· UL 508 Type 3R, 4, 4X and 12
· CSA Type 3R, 4, 4X and 12
· Complies with
◦NEMA 3R, 4, 4X, 12 and 13
◦IEC 60529, IP 66

CONSTRUCTION MOTOR
· Formed 316 stainless steel, 16 Gauge. DRIVER
· Smooth, continuously welded seams, ground smooth. MOUNTED
· Formed lip on enclosure to exclude flowing liquids and contaminants. TO TOP
· Door latches feature the added safety of quarter turn slot requiring use of tool WALL ! Attention !
For Proper Actuator Operation:
for opening. 1. Signal Level Cables must remain separate
from High Voltage cables in a separate tray
3. Maintain shield coverage of the Signal
cables all the way to the terminal block.

· Seamless poured-in place gasket for door cover.

or conduit: 4. Rexa Motor and Power cables must be kept
a.) Keep cables separate by at least 1 meter. away from sensitive equipment and
2. Maintain shield coverage of the Motor Power associated wiring by at least 1 meter.

· Oil resistant gaskets are permanently secured at 4 gland plate cutouts.

cable all the way to the terminal block. 5. Rexa Feedback cables must be at least 1
meter away from High Voltage cables.

· Collar studs provided for mounting inner panel.

· Bonding stud provided on door and grounding stud installed in enclosure.
· Stainless steel hinge pins and quarter turns.
· Approximate Weight with Contents Installed is 45 Pounds (20.4 Kilograms).
FINISH
· Cover/Enclosure & Gland Plates are natural stainless steel with a smooth
brushed finish. TOP VIEW

16.78 Ø0.44 16.00

[426.16] [Ø11.13] [406.40]
11.01 13.75
[279.60] [349.26]
10.00
[254.00]

DISPLAY SHUTS OFF

! AFTER EXTENDED
PERIOD OF KEYPAD
INACTIVITY

PRESS ANY
KEY TO WAKE
UP DISPLAY
AUTO MANUAL ENTER

19.00
[482.59]
POWER

NO I 8
AUTO MANUAL ENTER
18.83
18.00 [478.28]
[457.19] (1/4 TURN
FLIP UP DISPLAY BEZEL COVER LATCH)
SHOWN IN THE OPEN POSITION.

16.00
[406.40]

LEFT SIDE VIEW FRONT VIEW

13.38 GLAND
[339.73] PLATE 11.87
[301.51]

10.82
[274.85] 6.31 8.84
5.88 [160.27] [224.61]
[149.23] Feedback Stepper Module

10.00
[254.00]
2.75
[69.85]

BOTTOM VIEW BOTTOM VIEW 5.85

No Quick Connects With Quick Connects [148.59]

P. Interconnect Diagrams & Control Enclosure Drawings

 P-3 P. Interconnect Diagrams & Control Enclosure Drawings

B and C Stepper 115 VAC Wiring Diagram

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 P-4

B and C Stepper 230 VAC Wiring Diagram

P. Interconnect Diagrams & Control Enclosure Drawings

 P-5 P. Interconnect Diagrams & Control Enclosure Drawings

2C Stepper Enclosure Diagram

STANDARDS
· UL 508 Type 3R, 4, 4X and 12
· CSA Type 3R, 4, 4X and 12
· Complies with
◦NEMA 3R, 4, 4X, 12 and 13
◦IEC 60529, IP 66

CONSTRUCTION MOTOR
· Formed 316 stainless steel, 16 Gauge. DRIVER
· Smooth, continuously welded seams, ground smooth. MOUNTED
· Formed lip on enclosure to exclude flowing liquids and contaminants. TO TOP
· Door latches feature the added safety of quarter turn slot requiring use of tool WALL ! Attention !
For Proper Actuator Operation:
for opening. 1. Signal Level Cables must remain separate
from High Voltage cables in a separate tray
3. Maintain shield coverage of the Signal
cables all the way to the terminal block.

· Seamless poured-in place gasket for door cover.

or conduit: 4. Rexa Motor and Power cables must be kept
a.) Keep cables separate by at least 1 meter. away from sensitive equipment and
2. Maintain shield coverage of the Motor Power associated wiring by at least 1 meter.

· Oil resistant gaskets are permanently secured at 4 gland plate cutouts.

cable all the way to the terminal block. 5. Rexa Feedback cables must be at least 1
meter away from High Voltage cables.

· Collar studs provided for mounting inner panel.

· Bonding stud provided on door and grounding stud installed in enclosure.
· Stainless steel hinge pins and quarter turns.
· Approximate Weight with Contents Installed is 45 Pounds (20.4 Kilograms).
FINISH
· Cover/Enclosure & Gland Plates are natural stainless steel with a smooth
brushed finish. TOP VIEW

16.78 Ø0.44 16.00

[426.16] [Ø11.13] [406.40]
11.01 13.75
[279.60] [349.26]
10.00
[254.00]

DISPLAY SHUTS OFF

! AFTER EXTENDED
PERIOD OF KEYPAD
INACTIVITY

PRESS ANY
KEY TO WAKE
UP DISPLAY
AUTO MANUAL ENTER

19.00
[482.59]
POWER

NO I 8
AUTO MANUAL ENTER
18.83
18.00 [478.28]
[457.19] (1/4 TURN
FLIP UP DISPLAY BEZEL COVER LATCH)
SHOWN IN THE OPEN POSITION.

16.00
[406.40]

LEFT SIDE VIEW FRONT VIEW

13.38 GLAND
[339.73] PLATE 11.87
[301.51] Stepper Module

10.82
[274.85] 6.31 8.84
5.88 [160.27] [224.61]
[149.23] Feedback Stepper Module

10.00
[254.00]
2.75
[69.85]

BOTTOM VIEW BOTTOM VIEW 5.85

No Quick Connects With Quick Connects [148.59]

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 P-6

2C Stepper 115VAC Wiring Diagram

P. Interconnect Diagrams & Control Enclosure Drawings

 P-7 P. Interconnect Diagrams & Control Enclosure Drawings

1/2D and D Servo Enclosure Diagram

STANDARDS
· UL 508 Type 3R, 4, 4X and 12
· CSA Type 3R, 4, 4X and 12
· Complies with
◦NEMA 3R, 4, 4X, 12 and 13
◦IEC 60529, IP 66

CONSTRUCTION MOTOR
· Formed 316 stainless steel, 16 Gauge. DRIVER
· Smooth, continuously welded seams, ground smooth. MOUNTED
· Formed lip on enclosure to exclude flowing liquids and contaminants. TO TOP
· Door latches feature the added safety of quarter turn slot requiring use of tool WALL ! Attention !
For Proper Actuator Operation:
for opening. 1. Signal Level Cables must remain separate
from High Voltage cables in a separate tray
3. Maintain shield coverage of the Signal
cables all the way to the terminal block.

· Seamless poured-in place gasket for door cover.

or conduit: 4. Rexa Motor and Power cables must be kept
a.) Keep cables separate by at least 1 meter. away from sensitive equipment and
2. Maintain shield coverage of the Motor Power associated wiring by at least 1 meter.

· Oil resistant gaskets are permanently secured at 4 gland plate cutouts.

cable all the way to the terminal block. 5. Rexa Feedback cables must be at least 1
meter away from High Voltage cables.

· Collar studs provided for mounting inner panel.

· Bonding stud provided on door and grounding stud installed in enclosure.
· Stainless steel hinge pins and quarter turns.
· Approximate Weight with Contents Installed is 45 Pounds (20.4 Kilograms).
FINISH
· Cover/Enclosure & Gland Plates are natural stainless steel with a smooth
brushed finish. TOP VIEW

16.78 Ø0.44 16.00

[426.16] [Ø11.13] [406.40]
11.01 13.75
[279.60] [349.26]
10.00
[254.00]

DISPLAY SHUTS OFF

! AFTER EXTENDED
PERIOD OF KEYPAD
INACTIVITY

PRESS ANY
KEY TO WAKE
UP DISPLAY
AUTO MANUAL ENTER

19.00
[482.59]
POWER

NO I 8
AUTO MANUAL ENTER
18.83
18.00 [478.28]
[457.19] (1/4 TURN
FLIP UP DISPLAY BEZEL COVER LATCH)
SHOWN IN THE OPEN POSITION.

16.00
[406.40]

LEFT SIDE VIEW FRONT VIEW

GLAND
PLATE
13.38
[339.73] 11.87
[301.51]
6.31
10.82 [160.27] HTR/SOL

[274.85] 8.84
5.88 [224.61]
[149.23] Feedback Resolver Servo Motor

10.00
[254.00]
2.75
[69.85]

BOTTOM VIEW BOTTOM VIEW 5.85

No Quick Connects With Quick Connects [148.59]

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 P-8

½ D Servo 115VAC Wiring Diagram

P. Interconnect Diagrams & Control Enclosure Drawings

 P-9 P. Interconnect Diagrams & Control Enclosure Drawings

D Servo 230 VAC Wiring Diagram

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

 STANDARDS
· UL 508 Type 3R, 4, 4X and 12
· CSA Type 3R, 4, 4X and 12
· Complies with
◦NEMA 3R, 4, 4X, 12 and 13
◦IEC 60529, IP 66
CONSTRUCTION
· Formed 16 gauge 316 stainless steel.
16.97 · Continuously welded seams ground smooth.
[430.92] · Door stiffeners are provided where required for increased
strength and rigidity - designed to also permit additional
11.20 mounting options.
[284.36]
TOP VIEW
· Formed lip on enclosure to exclude flowing liquids and
20.00 contaminants.
10.00 [508.00] Ø0.39 · Door latches feature the added safety of quarter turn slot
[254.00] 18.50 [Ø9.91] requiring use of tool for opening.
[469.90] · Seamless poured-in place gasket for door cover.
· Oil resistant gaskets are permanently secured at 5 gland
plate cutouts.
· Collar studs provided for mounting inner panel
· Bonding stud provided on door and grounding stud installed
DISPLAY SHUTS OFF in enclosure.
AFTER EXTENDED
! PERIOD OF KEYPAD
INACTIVITY
Xpac Series 3 - Installation and Operation Manual - 9/22

PRESS ANY
· Stainless steel hinge pins and quarter turns.
KEY TO WAKE
UP DISPLAY
AUTO MANUAL ENTER · Approximate Weight with Contents Installed is 65 Pounds
22.62 (30 Kilograms).
[574.52] FINISH
POWER
· Cover and enclosure are natural stainless steel with a
smooth brushed finish.

NO I 8
AUTO MANUAL ENTER
5 GLAND PLATES
WITH GASKETS
21.56
[547.67]
FLIP UP DISPLAY BEZEL (1/4 TURN
COVER SHOWN IN THE LATCH)
OPEN POSITION.
Resolver 2 HTR/SOL

MOTOR 20.00
DRIVER [508.00] Feedback 2 Servo Motor
MOUNTED 8.84
TO LEFT 6.31
[224.61]
Resolver
SIDE WALL Feedback
[160.27] Servo Motor 2

2.75
[69.85]

FRONT VIEW BOTTOM VIEW 5.85

LEFT SIDE VIEW [148.59]

P. Interconnect Diagrams & Control Enclosure Drawings

P-10

Dual 1/2D and D Servo Enclosure Diagram

 P-11 P. Interconnect Diagrams & Control Enclosure Drawings

2D Servo 230 VAC Wiring Diagram

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

 STANDARDS
· UL 508 Type 3R, 4, 4X and 12
· CSA Type 3R, 4, 4X and 12
· Complies with
◦NEMA 3R, 4, 4X, 12 and 13
◦IEC 60529, IP 66
CONSTRUCTION
· Formed 16 gauge 316 stainless steel.
16.97 · Continuously welded seams ground smooth.
[430.92] · Door stiffeners are provided where required for increased
strength and rigidity - designed to also permit additional
11.20 mounting options.
[284.36]
TOP VIEW
· Formed lip on enclosure to exclude flowing liquids and
20.00 contaminants.
10.00 [508.00] Ø0.39 · Door latches feature the added safety of quarter turn slot
[254.00] 18.50 [Ø9.91] requiring use of tool for opening.
[469.90] · Seamless poured-in place gasket for door cover.
· Oil resistant gaskets are permanently secured at 5 gland
plate cutouts.
· Collar studs provided for mounting inner panel
· Bonding stud provided on door and grounding stud installed
DISPLAY SHUTS OFF in enclosure.
AFTER EXTENDED
! PERIOD OF KEYPAD
INACTIVITY
Xpac Series 3 - Installation and Operation Manual - 9/22

PRESS ANY
· Stainless steel hinge pins and quarter turns.
KEY TO WAKE
UP DISPLAY
AUTO MANUAL ENTER · Approximate Weight with Contents Installed is 65 Pounds
22.62 (30 Kilograms).
[574.52] FINISH
POWER
· Cover and enclosure are natural stainless steel with a
smooth brushed finish.

NO I 8
AUTO MANUAL ENTER
5 GLAND PLATES
WITH GASKETS
21.56
[547.67]
FLIP UP DISPLAY BEZEL (1/4 TURN
COVER SHOWN IN THE LATCH)
OPEN POSITION.
Resolver 2

MOTOR 20.00
DRIVER [508.00] HTR/SOL
MOUNTED 6.31 8.84
TO LEFT [160.27] [224.61]
SIDE WALL Resolver Feedback Servo Motor

2.75
[69.85]

FRONT VIEW BOTTOM VIEW 5.85

LEFT SIDE VIEW [148.59]

P. Interconnect Diagrams & Control Enclosure Drawings

P-12

D,P9 Servo 230 VAC Enclosure Diagram

 P-13 P. Interconnect Diagrams & Control Enclosure Drawings

D,P9 Servo 230 VAC Wiring Diagram

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

 18.99
[482.26]
13.22 24.00
[609.60] Ø0.39
[335.70]
12.00 22.54 [Ø9.91]
[304.80] [572.44]

1/4 TURN
LATCH

DISPLAY SHUTS OFF

AFTER EXTENDED
! PERIOD OF KEYPAD
INACTIVITY

PRESS ANY
KEY TO WAKE
UP DISPLAY
AUTO MANUAL ENTER

POWER
26.45
[671.88]

NO I 8
AUTO MANUAL ENTER

25.56
[649.27]
FLIP UP DISPLAY BEZEL
COVER SHOWN IN THE
OPEN POSITION.
24.00
[609.60]

1/4 TURN
LATCH
Xpac Series 3 - Installation and Operation Manual - 9/22

LEFT SIDE VIEW FRONT VIEW BACK VIEW

STANDARDS
· UL 508 Type 3R, 4, 4X and 12
GLAND
PLATE 5 GLAND PLATES · CSA Type 3R, 4, 4X and 12
WITH GASKETS · Complies with
◦NEMA 3R, 4, 4X, 12 and 13
◦IEC 60529, IP 66
CONSTRUCTION
20.88 · Formed 14 gauge 316 stainless steel.
[530.23]
Resolver 2
· Continuously welded seams ground smooth.
· Door stiffeners are provided where required for increased strength and rigidity
HTR/SOL
- designed to also permit additional mounting options.
6.31 8.84 · Formed lip on enclosure to exclude flowing liquids and contaminants.
5.88 [160.27] [224.61]
[149.23] Feedback Resolver Servo Motor · Door latches feature the added safety of quarter turn slot requiring use of tool
for opening.
· Seamless poured-in place gasket for door cover.
2.75 · Oil resistant gaskets are permanently secured at gland plate cutouts.
[69.85]
· Collar studs provided for mounting inner panel.
BOTTOM VIEW BOTTOM VIEW 5.85 · Bonding stud provided on door and grounding stud installed in enclosure.
[148.59] · Stainless steel hinge pins and quarter turns.
No Quick Connects with Quick Connects
· Approximate Weight with Contents Installed is 100 Pounds (45 Kilograms).
FINISH
· Cover and enclosure are natural stainless steel with a smooth brushed finish.

P. Interconnect Diagrams & Control Enclosure Drawings

P-14

D,P20 Servo 230 VAC Enclosure Diagram

 P-15 P. Interconnect Diagrams & Control Enclosure Drawings

D,P20 Servo 230 VAC Wiring Diagram

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 P-16

D,P40 Servo 230 VAC Enclosure Diagram

STANDARDS
· UL 508 Type 3R, 4, 4X and 12
· CSA Type 3R, 4, 4X and 12
· Complies with
◦NEMA 3R, 4, 4X, 12 and 13
◦IEC 60529, IP 66

CONSTRUCTION
· Formed 14 gauge 316 stainless steel.
· Continuously welded seams ground smooth.
· Door stiffeners are provided where required for increased strength and rigidity
- designed to also permit additional mounting options.
· Formed lip on enclosure to exclude flowing liquids and contaminants.
· Door latches feature the added safety of quarter turn slot requiring use of tool
for opening.
· Seamless poured-in place gasket for door cover.
· Oil resistant gaskets are permanently secured at 6 gland plate cutouts.
· Collar studs provided for mounting inner panel.
· Bonding stud provided on door and grounding stud installed in enclosure.
· Stainless steel hinge pins and quarter turns.
· Approximate Weight with Contents Installed is 191 Pounds (87 Kilograms).
FINISH
· Cover and enclosure are natural stainless steel with a smooth brushed finish.

18.92
[480.67] TOP VIEW
13.22
Ø0.39 30.00
[335.70]
[Ø9.91] [762.00]
12.00 28.50
[304.80] [723.90]

32.45
[824.28] DISPLAY SHUTS OFF

! AFTER EXTENDED
PERIOD OF KEYPAD
INACTIVITY

PRESS ANY
KEY TO WAKE
UP DISPLAY
AUTO MANUAL ENTER

POWER

NO I 8
AUTO MANUAL ENTER

31.56
[801.67]
FLIP UP DISPLAY BEZEL
COVER SHOWN IN THE
OPEN POSITION.

30.00
[762.00]

LEFT SIDE VIEW FRONT VIEW BLANK GLAND PLATE

RECOMMENDED FOR
CUSTOMER CONTROL
WIRING ENTRY.

RECOMMENDED
20.88 CABLE ENTRY
[530.23] FOR MAIN
POWER INPUT.
GLAND
PLATE Resolver 2 Resolver

5.88
[149.23]
Servo Motor HTR/SOL Feedback

1.0" CONDUIT 1.0" CONDUIT

HOLE PLUG HOLE PLUG

BOTTOM VIEW BOTTOM VIEW

No Quick Connects with Quick Connects

P. Interconnect Diagrams & Control Enclosure Drawings

 P-17 P. Interconnect Diagrams & Control Enclosure Drawings

D,P40 Servo 230 VAC Wiring Diagram

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

 Q-1 Q. Contact Input Options

Q. Contact Input Options

Contact Inputs
Note: Refer to the Inputs menu, Signal Type parameter in the Modes of Operation & Control Parameters section.
Q.1 Signal Input Range
Voltage: OFF: 0 to 8 volts, AC or DC
ON: 22 to 120 volts, AC or DC
Undefined: 8 to 22 volts, AC or DC
Current: OFF: Less than 1 mA
ON: 1.8 mA to 10 mA; proportional to voltage
Impedance: 12K ohms
Electromechanical or solid state switching devices may be used to activate the control signal. The following points should be observed:

ON state: OFF state:

Most AC and many DC solid state switching devices require a The OFF state leakage current must be less than 1 mA. Diode clamps
minimum current flow in order to remain in the closed state. If this or RC snubber networks placed across mechanical relays and the
minimum current exceeds the input signal current at the activation semiconductor junctions of solid state switches will pass some
voltage, the current flow may be increased by adding a shunt resistor current in the OFF state. If this leakage exceeds 1 mA, a resistor added
across the input signal terminals of the pulse auxiliary board. across the input signal terminals will bypass the current.

Q.2 1 Cont
The single contact ( 1 Cont ) option of controlling the actuator is for ON/OFF applications. A live voltage is applied to the Contact
Inputs Board.

When Signal Type = 1 Cont (one contact), “two position” operation—open/closed position—is selected. The applied signal defines
actuator position. If the Open input is active (powered), the actuator goes to Position Hi. If the Open input is not active (un-
powered), the actuator goes to Position Lo.

Note: Actuator will continue to move in desired direction as long as a signal is present or until target is reached.

Refer to certified drawing for wiring details.

Q.3 2 Cont
The dual contact ( 2 Cont ) option of controlling the actuator is for manual modulation control, using two signals. Two live voltages
are applied to the Contact Inputs Board.

When Signal Type = 2 Cont (two contacts), “manual modulation” operation is selected. The main input signals are the Main contacts Open and
Close inputs of the Contact Input Board. If both inputs are active or inactive, the actuator remains in its current position. If only the Open input
is active, the actuator travels towards Position Hi. If only input Close is active, the actuator travels towards Position Lo.

Note: Actuator will continue to move in desired direction as long as a signal is present or until target is reached.

Refer to certified drawing for wiring details.

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 R-1

R. Remote Manual Control

R.1 Remote Manual (RemoteMan)

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

RemoteMan allows the actuator to operate manually from a remote location. Once the Remote Manual mode is entered, the current
status will be displayed along with Position.

The RemoteMan mode is only accessible if the Contacts Input board is installed on top of the CPU. Refer to certified drawing for
wiring details.

The RemoteMan mode will be entered when the MAN Input of the Remote Auto/MAN Inputs is activated. The actuator is then
controlled by activating the Open or Close Inputs of the Remote Auto/MAN Input.

R. Remote Manual Control

 S-1 S. Safety Manual for ESD SIL Compliance

S. Safety Manual for ESD SIL Compliance

S.1 General
This REXA Actuator is a Type A device with a hardware fault tolerance (HFT) of 0. It has a safety trip function designed to meet
or exceed IEC 61508 requirements for a SIL 3 capable designed process. The actuator is verified to withstand the worst expected
environmental conditions listed in the IOM and specification sheet. This chapter covers the operating requirements for the end user
to ensure their system operates safely in accordance with the rated SIL level. The time in which an actuator will transition into a safe
state is defined as the time required to trip on the REXA data sheet. This transition time must be reviewed against the process safety
time to insure this product is appropriate for the application.

Any deviation to installation, operation or maintenance will void the IEC61508 SIL certification and may impact the actuator’s ability
to operate safely. All product failures should be reported to REXA. The FMEDA report for failure rates, failure modes, and proof
test information can be found in the REXA report KOS 13-10-03 R0001, titled FMEDA REXA, Xpac. An example of the system and
application environment in which the product will be embedded once delivered is shown in the following drawing.

S.2 System Set Up

In order to properly set up the ESD control system the following measures must be taken:

1. The actuator must to be calibrated to the driven device; refer to the Mechanical and Electrical installation section of this manual.

2. The actuator end points need to be set. Reference the section of this IOM on setting mechanical end stops.

S.3 System Operation

The primary safety function of the actuator is to place the driven device in the process safe position when input to the actuator’s
solenoid valves is de-energized. The safety function that carries the SIL certification is an ESD trip function. This trip function is designed
to ensure the actuator can be stroked in one direction to either the full open or the full closed position. This function needs to be
controlled directly from the user’s SIS and not through the REXA control box. The ESD is certified for low demand fail safe applications.

3.1. The safety solenoids defined on

the hydraulic schematic must
be wired directly into the main
safety system. It is possible for the
REXA controller to control these
solenoids but in order to minimize
the number of components in the
safety loop they must be wired
directly into the safety system for
SIL applications.

3.2. Since the safety solenoids are

controlled directly by the safety
system a trip relay must be installed
to disable the REXA electronics
during a safety event. This relay
will insure the REXA electronics
cannot react to the safety system
taking control of the actuator. Figure S-1: Example Safety Instrumented Function

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 S-2

3.3. This system is designed to full stroke at the rate shown on the provided actuator data sheet provided for this specific order.
3.4. The actuator’s useful life is 10 years based on the provided duty cycle. After recommended seal maintenance the actuators’
useful life is 20 years.
3.5. The REXA Actuator is available in normally open or normally closed ESD configurations.
3.6. A 24 hour mean time to repair should be assumed for safety availability calculations.
S.4 Safety Critical Components
4.1. Definition - Some of the components on this actuator are identified as safety critical. If the failure of any component would
inhibit the safety function of this REXA Actuator it is deemed a Safety critical component.
4.2. Only OEM supplied replacement parts can be used as suitable replacement parts for any component identified as Safety critical.
4.3. This actuator was supplied to meet a strict number of specifications and may not be modified in the field.
S.5 System Diagnostics
5.1. Built into the REXA CPU are numerous diagnostics that can be found in the error codes section of this IOM. These error
codes must be monitored by the safety system through an alarm relay. The only critical alarmed feature that would indicate
the system may not perform its intended trip function is the stall alarm.
5.1.1. Stall Alarm – If the actuator fails to move 1%, within the adjustable stall time setting, while positioning thealarm
relay will open indicating an alarm event.
5.1.2. Partial stroke testing is performed to verify the actuator is capable of performing it’s intended safety function. The
actuator shall be designed to support proof test intervals of 1 year or greater while consuming less than 40% of the
allowable PFDavg for SIL 2 SIF applications when PST is implemented. The control and design of this test should be in
the scope of the control system. The REXA Actuator will only follow the requested change in position as defined by the
control loop. This PST percentage to activate needs to be calibrated within the scope of the plants SIS system. During a
partial stroke test the control system must monitor the position transmitter to insure the actuator actually successfully
performed this function. The control room supervisor needs to review and sign off on the results of the proof tests. This
PST should be sufficient to achieve a greater than 65% SFF (Safe Failure Fraction). Key points to review during this test:
5.1.3. Verification from the REXA position transmitter that the actuator followed the change in the control position and
performed its PST function.
5.1.4. Redundant verification from an optional PST limit switch can be provided, this limit switch needs to be wired
directly into the SIS system.
5.2. The test results are to be recorded and stored for the life of the product.
5.3. Strict adherence to this manual will ensure this system will function as designed.
S.6 Site Acceptance Test Procedures
A cognizant engineering supporting the operation of the system is responsible for assigning individuals to conduct and record
automated testing and proof testing of the equipment. The cognizant engineer is then responsible for reviewing the results.
6.1. Run the actuator open and verify stroking times meet the specification sheet.
6.2. Run the actuator close and verify stroking time meet the specification sheet.
6.3. Perform an ESD trip and verify stroking time meet the specification sheet.
6.4. Run the actuator to it’s PST position to verify position feedback and the optional PST limit switch is functioning properly.
S.7 Environmental Requirements
7.1. The actuator has been designed and verified to withstand the worse case environmental conditions as listed in this IOM.

S. Safety Manual for ESD SIL Compliance

 T-1 T. Position Transmitter

T. Position Transmitter

T.1 Position Transmitter

The position transmitter provides a two-wire 4-20 mA signal that is proportional to actuator position. The transmitter’s output is
optically isolated from the electronics. Both an active and passive transmitter are available. A passive position transmitter is similar
to other two-wire transmitters in that an external dc power source is required. An active two-wire transmitter with its own 24 Vdc
power supply is available.

Note: Position feedback can be changed in the field from active to passive or passive to active by rewiring the feedback. Refer to
certified drawing for wiring details.

Refer to OUTPUTS Menu (6.1.8) in Modes of Operation & Control Parameters for calibration procedures.

Passive Active
Resolution <0.1% of full stroke
Maximum External Load 1000 ohms @ 36 Vdc 700 ohms @24 Vdc
Minimum Supply Voltage 10 + (0.02 x RLOAD) Vdc 24 Vdc
Maximum Supply Voltage 36 + (0.004 x RLOAD) Vdc (internal supply)

Whenever the actuator is unable to follow the applied control signal, the Alarm Relay will change state (de-energize).

Alarm Relay:

Response: ½ second of any “fail to operate condition”

Alarm Contacts: SPST

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

Connection: Terminal strip on the auxiliary board

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 U-1

U. Electronic Relays
Limit Switch, Alarm, and Warning

Electronic Relays
The electronic limit, not in auto, alarm and warning relays are located on the interconnect board. An indicator LED shows the status
(energized-ON) of each relay.

Two of the relays are configured in the Setup Mode to activate upon user defined stroke limits. The third relay is an alarm indicator
and the fourth is a warning indicator. The fifth indicates the system is not in auto mode.

U.1 Limit Switch Relays

LED D6 will illuminate when the Relay 1 is active; indicating the actuator position is at, or below, the value set in parameter Relay 1.

LED D10 will illuminate when the Relay 2 is active; indicating the actuator position is at, or above, the value set in parameter Relay 2.

U.2 Alarm and Warning Relay

LED’s D12 and D16 on the interconnect board are always active and lit when the actuator operates normally without any error and is
following the control signal. Once the actuator detects an error, the Alarm and Warning Relays open and LEDs D12 and D16 will turn off.

When the CPU detects an error, which opens the Warning Relay only, LED D16 will turn off. The Warning relay is a signal from the
control enclosure that means the REXA CPU detects a problem but can still operate and follow the Control Signal.

The Alarm relay is a signal from the control enclosure that means the REXA CPU detects a problem, and cannot follow the Control Signal.

When the system is put into Local or Setup modes, LED D8 will turn off.

If PST is configured to PST confirm (from GUI only), the LED D8 is ON until PST cycle is active. When PST cycle reaches the PST target
the LED turns off, then illuminates when the actuator has motored back to 100% position.

Refer to certified drawing for warning alarm and relay wiring details.

General Specifications
Quantity: 4 (2 Limit, 1 Warning, 1 Alarm)
Type High Capacity PhotoMOS Relay
Rating 1 amp @ 200 VAC/VDC
Turn On Time: <3 mS
Differential Travel (Hysteresis): 0.1%
Connection: Terminal strip on the CPU board

U. Electronic Relays- Limit Stiwtch, Alarm, and Warning

 X-1 X. Cable Installation Guide for Power and Control Cables

X. Cable Installation Guide for Power and Control Cables

Note: Information within this document is based on best practices. For complete installation guidelines, standards, and restrictions please
consult applicable electrical code for the region of installation.

X.1 Connector Installation

Our connectors are designed to be able to be connected by hand and meet the rated ingress protection for the product. We do
not recommend the use of a wrench with our products for tightening unless it is a torque wrench with the proper torque setting.

Recommended torque for tightening Mini 7/8” + 1” connectors: 2 Nm

X.2 Cable Support

Cables should be supported to prevent movement on the equipment. Ideally the cable should be supported in a distance not to
exceed 1.8m (6ft) without continuous support. The cable should also be supported at any connection points or terminations so that
tension is not transmitted to joints or terminals.

X.3 Proper Bend Radius

Minimum bend radius for Fixed Applications: Standard cable - 10x cable diameter

X.4 Tying Cables with Cable Ties

When tying cable with self-locking cable ties, always leave the ties loose enough for the cables to slide freely under the tie. Over
tightening will create stress concentrations that can cause the conductors to fail prematurely. Never tighten the tie to the point
where the cable jacket becomes deformed.

X.5 Eliminating Stress Points in Cable Dress

Installing cables to allow for adequate stress loops and freedom of motion increase the life of the cables.

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 Y-1

Y. Basis Weight Control

Y.1. Control Overview

24VDC Increase input, when active the actuator moves in one direction

24VDC decrease input, when active the actuator moves in the other direction

These 24VDC signals are issued in pulses and pulse time duration corresponding to the magnitude of the actuator’s movement.

Y.2. Typical Pulse Response

Based on field testing Rexa has validated the following typical % of actuator movement based on the total time the 24VDC pulse is active
for small setpoint changes.

Y.3. REXA Menu Parameters

1. Deadband – This is a read only parameter in this version of software and cannot be adjusted directly. It is represented based on
the Abs Deadb value below.

2. Abs Deadb – Range 8-500; default 10 Note: when you change these values the actual read only deadband value will adjust. This
parameter gives you more resolution than you can see by incrementing the true deadband.

a. Set to 8 as a default

3. Pulse Width – range 100ms -10000ms; default 300ms

a. This is the pulse duration time that will achieve a 1% movement. (Actual pulse time / Pulse Width ) x 1% = Actual
movement

b. Adjusting Pulse Width higher results in the actuator making a smaller moves for a fixed pulse duration.

c. Set to 2500 as a default

4.Filter – Total number of control loop cycles that the actuator is out of deadband before the actuator will move.

a. Increasing this value filters out noise but makes the actuator’s response slower.

b. Set to 12 as a default

5.Normal parameters that still work in this custom code that should be used if the unit is overshooting

a. Gain

i. Set to 50 as a default

b. High speed

i. Set to 100%

Y. Basis Weight Control

 Z-1 Z. Air Ship Fill Procedures

Z. Air Ship Fill Procedures

Z.1. Accumulator Systems

Caution: Carefully read and perform this procedure before powering on your REXA actuator.

This actuator was prepared for air transportation and required to comply with IATA’s hazardous goods regulations. Prior to shipment,
the accumulator nitrogen pressure was lowered to 20 psi (1.38 bar). The accumulator nitrogen pressure must be restored to normal
levels before the actuator can be powered on. The instructions below outline how to use compressed nitrogen to properly restore
the accumulator nitrogen pressure.

Procedure:
1. Determine accumulator bottle oil capacity by tag. See Figure 1 below. Use Table 1 below to determine nitrogen volume value.

Figure 1
Accumulator Capacity Nitrogen Volume@ Nitrogen Volume@
3000 psi (206 bar) 4000 psi (275 bar)

116 500 cu. in (8.19L) 375 cu. in (6.14L)

231 1048 cu. in (17.1L) 786 cu. in (12.9L)
578 2436 cu. in (39.9L) 1824 cu. in (29.9L)
1155 4832 cu. in (79.1L) 3624 cu. in (59.4L)
1733 7144 cu. in (117L) 5358 cu. in (87.8L)
2310 9452 cu. in (155L) 7089 cu. in (116L)

Table 1

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 Z-2

2. Locate and remove the gas valve guard and gas valve cap. See Figure 2 below.

Figure 2

3. Add nitrogen using appropriate charge kit (REXA part number K09851-3000). See Figure 3 below. Using the Pre-Charging
Procedure on the next page, add nitrogen until the pressure reaches what is shown on the bottle tag. See Figure 4.

Note: The nitrogen needs to be added slowly to allow the temperature to stabilize. After the full amount is added wait one hour and
recheck pressure.

Figure 3 Figure 4

Z. Air Ship Fill Procedures

 Z-3 Z. Air Ship Fill Procedures

Pre-charging Procedure:

• Back out the gas chuck “T” handle (Figure 3: Item 1) all the way (counter-clockwise) before attaching charging assembly to
accumulator gas valve.

• Close the bleed valve (Figure 3: Item 2)

• Attach swivel nut (Figure 3: Item 3) to gas valve and tighten (10-15 in. lb. [11.5-17 cm kg]). Make sure not to loop or twist
the hose.

• Turn the gas chuck “T” handle until the gauge starts showing the pressure in the accumulator. Do not turn the “T” handle all
the way down, as it will damage the valve core.

• For the gas valve shown in Figure 6, hold the gas valve at point “C” with one wrench while unscrewing the hex nut at point
“D” with a second wrench. This will open the poppet inside the gas valve.

○ Note: Three turns will fully open the valve.

• Open the nitrogen bottle valve and slowly fill accumulator. Shut off when gauge indicates desired pre-charge.

• Let the pre-charge set for 10 to 15 minutes. This will allow the gas temperature to stabilize. If the desired pre-charge is
exceeded, close nitrogen bottle valve, then slowly open bleed valve. Do not reduce pre-charge by depressing valve core
with a foreign object. High pressure may rupture rubber valve seat.

• When finished pre-charging the accumulator, turn “T” handle all the way out on the gas chuck (Figure 3: Item 1), then
open the bleed valve (Figure 3: Item 2).

For the gas valve as shown in Figure 6, with a wrench, tighten hex nut at point “D” to close internal poppet (5-8 ft. lbs. [5.7-9.2 cm
kg]).

Hold the gas valve to keep from turning, loosen swivel nut, and remove assembly. Check for pre-charge leak using a common leak
reactant.

Replace the gas valve cap (10-15 in. lbs. [11.5-17 cm kg]) and valve guard. (The gas valve cap serves as a secondary seal.)

Figure 5 Figure 6

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 Z-4

Z.2. Oil Fill Procedure

This actuator was prepared for air transportation and was required to comply with ITAR’s hazardous goods regulations. The internal
thermal expansion tank pressure was dropped to 20 PSI. This needs to be filled back up to 75 PSI using REXA’s standard oil, Castrol
SAE 5W-50 motor oil. If 5W-50 is not available, other oils may be substituted*. However, using other oils may result in a derating of
the actuator low and/or high temp rating. Refer to table 1 below

Oil Grade Low Temp Limit Derating High Temp Limit Derating
5W-50 None None
5W-40 None 170˚F (76˚C)
10W-30 25˚F (-4˚C) 135˚F (57˚C)
15W-40 30˚F (-1˚C) 170˚F (76˚C)
*For actuators using specialty oil other than Castrol 5W-50 no substitutes are allowed.

Procedure:
1. Locate and remove the oil fil valve cover.

Figure 1

2. Fill the oil gun.

Figure 2

Z. Air Ship Fill Procedures

 Z-5 Z. Air Ship Fill Procedures

3. Purge any air out of the oil gun, line and fitting by pumping the handle several times until the level feels firm.

Figure 3

4. Depress the small valve in the center of the female Schrader fitting (on the oil pump) with a suitable tool such as a small
screwdriver or punch. Continue until oil flows freely without any signs of air bubbles.

Figure 5A Figure 4B

5. Attach the oil gun fitting to the actuator oil fill valve

Figure 5

REXA Xpac Series 3 - Installation and Operation Manual - 9/22

Xpac Series 3 - Installation and Operation Manual - 9/22 Z-6

6. Add oil until the thermal expansion chamber gauge reads within 70-80PSI.

Figure 6

7. Remove the oil gun fitting from the actuator fill valve.

8. Reinstall the fill valve cover on the actuator.

9. Drain and store the oil gun in a clean location.

Note: Do not overfill the thermal expansion chamber. While overfilling will not harm the actuator, overfilling will force oil from
the thermal expansion chamber. Overfilling will also cause oil weeping from the overfill protection due to thermal expansion.

Z. Air Ship Fill Procedure