electric - 50.244.15.1050.244.15.10/techlib/Rotork/Rotork_Actuator_IQ_install_D301.pdf · electric...

IQ RangeInstallation andMaintenance Instructions

Publication number E170E2Date of issue 03/01

electric

Please ensure that this publication is thoroughly read and understood

newcorrec56977.qxd 06/03/01 15:16 Page 1

Primary User

Rotork_Actuator_IQ_install_D301

The Rotork Setting Tool allows actuator control, indication and protection functionsto be configured to suit site requirements. It is essential that all the actuatorsettings are checked for compatibility with the process and control systemrequirements before the actuator is put into service. Please read this publication.

When Rotork personnel or nominated agents are contracted to carry out sitecommissioning and/or acceptance, documentation of commissioned actuatorconfiguration can be made available for customer record.


This manual provides instruction on:

* Manual and electrical (local and remote) operation.

* Preparation and installation of the actuator onto the valve.

* Subsequent commissioning and adjustment of the Primary Settings for correct valve operation.

* Commissioning and adjustment of the actuator Secondary Settings to suit site specific control and indication requirements.

* Maintenance – Troubleshooting.

* Sales and Service.

THE ROTORK IQ RANGE – THE FIRST VALVE ACTUATOR THAT YOUCAN COMMISSION AND INTERROGATE WITHOUT REMOVINGELECTRICAL COVERS.

Using the supplied infra-red Setting Tool to access the actuator set upprocedures, “point and shoot” setting of torque levels, position limits and allother control and indication functions can be made safely, quickly andconveniently, even in hazardous locations. The IQ allows commissioningand adjustment to be carried out with the main power supply to theactuator switched on or off.

Standard diagnostics access information about the control system, valveand actuator status in the form of display icons and help screens.

Instantaneous valve torque and position can be monitored on the actuatorwith a single key press of the Setting Tool.

The on board Datalogger captures operational and valve torque dataenabling informed maintenance choices to be made. IQ Insight softwarefor PC and/or the Rotork IS Communicator allows the Datalogger to beinterrogated, as well as the complete actuator set up to be configured andrecorded.

The actuator containing the Setting Tool will be identified with a yellowlabel on the terminal cover.

Visit our web site at www.rotork.com for more information on the IQ andother Rotork actuator ranges.



INDEXPage

1 Health and Safety 2

2 Storage 3

3 Operating your IQ Actuator 33.1 Operating by Hand 33.2 Operating Electrically 33.3 The Actuator Display – 4

Valve Position Indication 3.4 The Actuator Display – 5

Alarm Indication

4 Preparing the Drive Bush 74.1 IQ7 to IQ35 7

Thrust Base Types A and Z4.2 IQ7 to IQ35 7

Non Thrust Base Type B4.3 IQ40 to IQ95 8

Thrust Base Types A and Z4.4 IQ40 to IQ95 9

Non Thrust Base Type B

5 Mounting the Actuator 105.1 Rising Stem Valves – 11

Top Mounting5.2 Valve with Gearbox – 11

Side Mounting5.3 Non Rising Stem Valves – 11

Top Mounting5.4 Handwheel Sealing 115.5 IQM Modulating Actuators 125.6 IQML Linear Drive Unit 125.7 IQML Adjusting Linear Stroke 12

6 Cable Connections 146.1 Earth/Ground Connections 146.2 Removing Terminal Cover 146.3 Cable Entry 146.4 Connecting to Terminals 156.5 Replacing Terminal Cover 15

7 Commissioning 167.1 The Setting Procedure 167.2 The Setting Tool 177.3 Entering the Actuator 18

Setting Procedure7.4 Setting Mode – Password 187.5 New Password 18

7.6 Checking Mode 187.7 Procedure Branch – 19

Crossroad7.8 The Actuator Display – 19

Setting/Checking Mode7.9 Returning to Valve 19

Position Display

8 Commissioning –Primary Functions 20

Primary Functions Index 21

9 Commissioning –Secondary Functions 30

Secondary Functions Index 30

10 Maintenance, Monitoringand Troubleshooting 6110.1 Help Displays 6310.2 IrDA Diagnostics & Configuration 68

11 Weights and Measures 70Binary, Hexadecimal, Decimal 71Conversion Table

1


This manual is produced to enable acompetent user to install, operate,adjust and inspect Rotork IQ rangevalve actuators.The electrical installation,maintenance and use of theseactuators should be carried out inaccordance with the NationalLegislation and Statutory Provisionsrelating to the safe use of thisequipment, applicable to the site ofinstallation.For the UK: Electricity at WorkRegulations 1989 and the guidancegiven in the applicable edition of the“IEE Wiring Regulations" should beapplied. Also the user should be fullyaware of his duties under the Healthand Safety Act 1974.For the USA: NFPA70, NationalElectrical Code is applicable ®.The mechanical installation should becarried out as outlined in the manualand also in accordance with relevantstandards such as British StandardCodes of Practice.If the actuator has nameplatesindicating that it is suitable forinstallation in Hazardous Gas Areasthen the actuator is suitable for use inZone 1 and Zone 2 (or Div 1

and Div 2) explosive atmospheresonly. They should not be installed inatmospheres where gases arepresent with an ignition temperatureless than 135°C, unless suitability forlower ignition temperatures has beenindicated on the actuator nameplate.Any test instruments applied to theactuator should be of equivalentcertification. The electricalinstallation, maintenance and the useof these actuators should be carriedout in accordance with the code ofpractice relevant for that particularHazardous Gas Area certification.No inspection or repair should beundertaken unless it conforms to thespecific Hazardous Gas Areacertification requirements. Under nocircumstances should anymodification or alteration be carriedout on the actuator as this couldinvalidate the conditions under whichits certification was granted.Access to live electrical conductors isforbidden in the hazardous areaunless this is done under a specialpermit to work, otherwise all powershould be isolated and the actuatormoved to a non hazardous area forrepair or attention.

Only persons competent by virtue oftheir training or experience should beallowed to install, maintain and repairRotork actuators. Work undertakenmust be carried out in accordancewith instructions in the manual. Theuser and those persons working onthis equipment should be familiar withtheir responsibilities under anystatutory provisions relating to theHealth and Safety of their workplace.WARNING:Motor TemperatureWith excessive use the motor surfacetemperature could reach 132°C (270°F).Motor Thermostat BypassIf the actuator is configured to bypassthe motor thermostat, when using theESD function, the hazardous areacertification will be invalidated.Control and IndicationWhere the actuator build allowsremote control and indicationsupplies higher than 150V a.c. butbelow 300V a.c. (refer to actuatorwiring diagram) the remote controland indication supplies must bederived from a supply which isdesignated as installation category(overvoltage category) ll as defined inBSEN 61010 (Safety Requirements

For Electrical Equipment formeasurement, control and laboratoryuse).Enclosure MaterialsIQ10 to IQ35 are manufactured fromaluminium alloy with stainless steelfasteners and the thrust bases aremanufactured in cast iron. IQ40 toIQ95 enclosures are manufactured inaluminium alloy and cast iron withstainless steel fasteners and thethrust bases are manufactured in castiron.The user must ensure that theoperating environment and anymaterials surrounding the actuatorcannot lead to a reduction in the safeuse of, or the protection afforded bythe actuator. Where appropriate theuser must ensure the actuator issuitably protected against itsoperating environment.Should further information andguidance relating to the safe use ofthe Rotork IQ range of actuators berequired, it will be provided onrequest.

Health and Safety1

2


If your actuator cannot be installedimmediately store it in a dry placeuntil you are ready to connectincoming cables.

If the actuator has to be installedbut cannot be cabled it isrecommended that the plastictransit cable entry plugs arereplaced with metal plugs which aresealed with PTFE tape.

The Rotork double sealedconstruction will preserve internalelectrical components perfectly ifleft undisturbed.

It is not necessary to remove anyelectrical compartment covers inorder to commission the IQactuator.

Rotork cannot accept responsibilityfor deterioration caused on siteonce the covers are removed.

Every Rotork actuator has beenfully tested before leaving thefactory to give years of trouble freeoperation, providing it is correctlycommissioned, installed and sealed.

Fig. 1

To engage handwheel drivedepress the Hand/Auto lever into“Hand” position and turn thehandwheel to engage the clutch.The lever can now be releasedwhen it will return to its originalposition. The handwheel willremain engaged until the actuatoris operated electrically when it willautomatically disengage and returnto motor drive. If required theHand/Auto lever can be locked ineither position using a padlock witha 6.5mm hasp.

Check that power supply voltageagrees with that stamped on theactuator nameplate. Switch onpower supply. It is not necessary tocheck phase rotation.

Do not operate the actuatorelectrically without firstchecking, using the infra-redSetting Tool, that at least theprimary settings have beenmade. (refer to section 8 page 20)

Selecting Local/Stop/RemoteOperationThe red selector enables eitherLocal or Remote control, lockablein each position using a padlockwith a 6.5mm hasp.

When the selector is locked in theLocal or Remote positions the Stopfacility is still available. The selectorcan also be locked in the Stopposition to prevent electricaloperation by Local or Remotecontrol.

Fig. 2

Local ControlWith the red selector positioned atLocal (anti-clockwise) the adjacentblack knob can be turned to selectOpen or Close. For Stop turn redknob clockwise.

Remote ControlRotate the red selector to theRemote position (clockwise), thisgives remote control only for Openand Close but local Stop can stillbe used by turning the red knobanti-clockwise.

Storage2 Operating your

IQ Actuator3

3

3.1 Operating by Hand 3.2 Operating Electrically


Fig. 3 The Actuator DisplayThe display consists of:1. Red – position indication lamp2. Yellow – position indication lamp3. Green – position indication lamp4. Liquid crystal display screen

(LCD)5. Infra-red sensors6. Infra-red signal confirmation

indicator (Red)

The liquid crystal display screenhas 2 modes of position indication:1. Valve position – power on2. Valve position – power off

On power up the actuator’s liquidcrystal display screen is back-litwith a “soft amber” light and one ofthe indicator lamps will be on,dependent on position. The displayscreen will show percentage openor an end of travel symbol.(See Figs 4.1, 4.2 and 4.3.)

As standard, red lamp signifiesvalve open, yellow intermediate,and green lamp signifies valveclosed. Open and closed colourfunctions can be reversed onrequest.

OpenRed indicator and open symboldisplayed

Mid TravelYellow indicator and percentageopen value displayed

ClosedGreen indicator and closed symboldisplayed

With the mains supply switched off,the liquid crystal display screen ispowered by a battery andcontinues to display actuatorposition. However, the batterydoes not support screen back-lighting, or position indicator lamps.

4

Fig. 4.2

Fig. 4.3Fig. 4.1

3.3 Display - Local Indication

5 6

3 1

2

4


5

The IQ display incorporates valve,control system, actuator andbattery alarm indication in the formof four display icons. Located in thetop portion of the display, eachicon represents certain alarm conditions. Standard help screensare also available to assist indetermining the actuatoroperational and alarm status.(refer to Help Screens page 63)

The valve alarm icon, figure 4.4 isdisplayed when a valve problemcauses the actuator to "trip-off" dueto the configured torque valuebeing developed. (refer to [tC] /[tO]page 25) The possible causes are:· Valve tight or obstructed in mid

travel.· Valve stuck or jammed· Valve process conditions changed

(increase in pressure, flow etc)

Once the actuator has tripped offon torque, electrical operation inthe same direction is inhibited. Theicon will remain displayed untilmovement in the opposite directiontakes place.

The valve alarm icon will not bedisplayed when stopping at end oftravel for valves configured totorque seat or torque back seat atend of travel. (refer to [C2] /[C3]page 23)

Try handwheel operation of thevalve to "feel" for stiffness. (refer topage 3)

The control system alarm icon,figure 4.5 is displayed when theremote control system maintainsan active ESD or interlock signal(the ESD, interlock function orconditional control having beenenabled).

Local and Remote operation will beinhibited while an active ESD orinterlock signal is present.(refer to [A1] ESD Action page 33,[A8] External Interlocks page 35and Conditional Control [A9]page 35)

Investigate the operationalconditions of the actuator remotecontrol system.

3.4 Display - Alarm Indication

Valve Alarm

Fig.4.4

Fig.4.5

Control Alarm


The actuator alarm icon, figure 4.6is displayed when an activeactuator alarm is present.

Electrical operation will be inhibitedwhile an alarm is present.The possible causes are:· Motor thermostat tripped· Battery low on power up*· Power supply fault· Actuator control system alarm*see Battery Alarm(To identify the specific cause ofthe alarm refer to Help Screenspage 63)

The battery alarm icon, figure 4.7is displayed when the actuatordetects its battery as being low,discharged or missing.

If, on power up, the actuatordetects a discharged battery andactuator power loss inhibit feature[OS] is enabled (refer to page 58),both battery and actuator alarmicons (figures 4.7 and 4.6) will bedisplayed. Electrical operation willbe inhibited.

When the battery alarm icon isdisplayed, the battery should bereplaced immediately. (refer topage 61)

The actuator checks the batterystatus at approximately 10 minuteintervals. After replacing a batterythe alarm icon will continue to bedisplayed until the next checkindicates the battery is healthy.This may take up to 10 minutes.

6

Battery Alarm

Fig.4.7

Actuator Alarm

Fig.4.6


Removal of Drive Bush forMachining

Fig. 5 Bronze Drive Bush Fitted intoThrust Taking Base.

Turn actuator onto its side, removethe two cap head screws holdingbase plate onto thrust base, pullout the drive bush complete with itsbearing assembly.

Before machining the drive bush,remove the thrust bearing from itas follows:-1. Locate and loosen the two grub

screws in the steel bearing stop ring.

Fig. 6 Components of Type A Thrust Base.

2. Unscrew the bearing stop ring from the drive bush, slide the bearing off the drive bush. Keep the stop ring and bearing in a safe, clean place ready forre-assembly.

3. Machine the drive bush to suit the valve stem, allowinggenerous clearance on screw thread for rising stem valves.Ensure that the male thread on the bush is not damaged.

Re-assembly1. Remove all swarf from the drive

bush, ensuring that the “O” rings on the drive bush and bearing stop rings are in good condition, clean and greased.

2. Slide bearing onto drive bush and ensure that it is fitted down to the shoulder.

3. Screw bearing stop ring with the grub screws uppermost onto the drive bush, tighten down and lock with the two grub screws.

4. Refit the drive bush assembly into the base casting on the actuator, ensuring that the slots in the drive bush are located intothe drive dogs of the hollow output shaft.

5. Refit the base plate and secure with cap headed screws.

Undo the four set screws securingthe base plate to the gearcase andremove the base plate.

The drive bush and its retainingclip can now be seen.

Types B3 and B4 removal:(refer to Fig 7a)Using external circlip pliers, expandthe circlip while pulling on the drivebush. The drive bush will detach

from the actuator centre columnwith the circlip retained in itsgroove.

Fig. 7a

Types B3 and B4 re-assembly:Grease drive bush and circlip.With the circlip fitted in its grooveoffer the drive bush up to theactuator centre column ensuringthe drive dogs are aligned.Expand the circlip while pushingthe drive bush into the centrecolumn. The drive bush will movefurther in. Release circlip pliersensuring the circlip is correctlyseated in both the drive bush andcentre column groovesReplace the base plate and fix withfour set screws

7

Preparing Drive Bush4

4.2 IQ10 to IQ35Non-Thrust Base Type B

4.1 IQ10 to IQ35Thrust Base Types A and Z


Fig. 7b

Type B1(refer to fig 7b)The procedure for removal andrefitting of the B1 drive bush is thesame as for B3 & B4, However thecirclip is replaced with a customspring clip. The spring clipoperates in the same manner asthe B3/B4 circlip but is expandedusing long nose pliers.

Removal of Drive Bush forMachiningEngage “hand” and turn handwheeluntil retainer set screw is visiblethrough hole in actuator base.

Fig. 8 Locating Set Screw

Loosen set screw and unscrewretainer using hammer and punch.Remove drive bush and machine tosuit valve stem or gearbox inputshaft.Allow generous clearance on screwthread for rising stem valves.

Fig. 9 Removal of Retainer

Fig. 10 Type A Drive Bush

If the actuator has a type A drivebush, (Fig 10) this can be fitted inposition 1 or 2 to suit the positionof the valve mounting flange.

Fig. 11 Type A Drive Bush in Position 1

Fig. 12 Type A Drive Bush in Position 2

8

4.3 IQ40 to IQ95 Thrust Base Types A and Z


If the actuator has a type Z3 drivebush (Fig. 13) this can only be fittedbelow the actuator base (Fig. 14).

Fig. 13 Type Z3 Drive Bush

Fig. 14 Type Z3 Drive Bush in Position 3

Re-AssemblyHaving confirmed the positionrequired, insert the machined drivebush ensuring that the actuatoroutput shaft dogs are in fullengagement with the bush.Fit drive bush retainer securely,turning clockwise until fullytightened using hammer andpunch. Rotate by hand wheel toalign retainer set screw with hole inthe side of base and tighten.

Fig. 15 Tightening Retainer Set Screw

Type B1Output shaft bored and keyed toISO 5210 standard. There is nodrive bush to machine.

Types B3 and B4Identical drive bushes secured bycap headed screws.

B3 is supplied pre-machined toISO 5210 standard.

B4 is supplied blank and must bemachined to suit the input shaft ofthe gearbox or valve that it willdrive.

Fig. 16 B3/B4 Drive Bush

Fig. 17 B3/B4 Drive Bush in Situ.

9

4.4 IQ40 to IQ95 –Non-Thrust Base Type B


(refer to Weights and Measures page 70 for actuator weights).

Ensure the valve is secure before fitting the actuator as the combinationmay be top heavy and therefore unstable.

If it is necessary to lift the actuator using mechanical lifting equipmentcertified slings should be attached as indicated in Fig.18a for vertical valveshafts and Fig.18b for horizontal shafts.

At all times trained and experienced personnel should ensure safe lifting,particularly when mounting actuators.

WARNING:The actuator should be fully supported until full valve shaftengagement is achieved and the actuator is secured to the valveflange.

A suitable mounting flange conforming to ISO 5210 or USA StandardMSS SP101 must be fitted to the valve.

Actuator to valve fixing must conform to Material SpecificationISO Class 8.8, yield strength 628 N/sq mm.

WARNING:Do not lift the actuator and valve combination via the actuator.Always lift the valve/actuator assembly via the valve.

Each assembly must be assessed on an individual basis for safe lifting.

10

Mounting the Actuator5

Fig. 18a

Fig. 18b


a) Fitting the Actuator and Base as a Combined Unit – All Actuator Sizes

Fig. 19

Fit the machined drive bush intothe thrust base as previouslydescribed, lower the actuator ontothe threaded valve stem, engage“hand” and wind the handwheel inthe opening direction to engagethe drive bush onto the stem.Continue winding until the actuatoris firmly down on the valve flange.Wind two further turns, fit securingbolts and tighten fully.

b)Fitting Thrust Base to Valve – Actuator Sizes 10 to 35 only

Fit the machined drive bush intothe thrust base as previouslydescribed. Remove the thrust basefrom the actuator, place it on thethreaded valve stem with theslotted end of the drive bushuppermost and turn it in theopening direction to engage thethread. Continue turning until thebase is positioned onto the valveflange. Fit securing bolts but do nottighten at this stage. Lower theactuator onto the thrust base and rotate the complete actuator until

the drive dogs on the actuatoroutput shaft engage into the drivebush. Actuator flange should nowbe flush with base flange.

Fig. 20

Continue to turn actuator untilfixing holes align. Using boltssupplied fix actuator to thrust baseand tighten down. Open valve bytwo turns and firmly tighten downfixings onto valve flange.

Check that the mounting flange isat right angles to the input shaft,and that the drive bush fits theshaft and keyway with adequateaxial engagement. Engage “hand”,offer up actuator to the input shaftand turn handwheel to alignkeyway and key. Tighten mountingbolts.

Treat as for side mounting exceptthat when thrust is taken in theactuator, a thrust nut must be fittedabove the drive bush and securelytightened.

Ensure that sealing plug in centreof handwheel (or spindle covertube depending on which is fitted)is sealed with PTFE tape and fullytightened, ensuring that moisturedoes not pass down the centrecolumn of the actuator.

11

5.1 Rising Stem Valves Top Mounting

5.2 Valve with GearboxSide Mounting

5.3 Non Rising Stem Valves Top Mounting

5.4 Handwheel Sealing


12

The IQM range of actuators aresuitable for modulating control dutyof up to 1200 starts per hour inaccordance with IEC 34-1 toS4 50%.

IQM actuators have a dynamicbraking facility as standard. Ifmechanical overrun of the actuatorand valve prove to be excessive foraccurate control, the brake can beenabled by fitting a link to theactuator terminal block as indicatedby the wiring diagram. Withdynamic braking enabled, motorheating effects increase andtherefore the number of actuatorstarts should be reduced toprevent motor thermostat tripping.(refer to publication E 410E for moreinformation.)

Commissioning of IQM rangeactuators is identical to thestandard IQ.(refer to Sections 7, 8 and 9commencing on page 16)

Consists of a lead screw assemblyarrangement attached to the baseof the actuator in order to provide alinear output stroke between 8mm(3/8in) minimum and 120mm (4 3/4in) maximum.

The IQML can be supplied with orwithout a yoke mounting adaptor,this adaptor consists of four pillarsand a base flange to suit the valve.

Fig. 21 IQML with Yoke

Fig. 22 IQML without Yoke

With actuator securely fitted tovalve, but with the linear drivedisconnected, ensure valve is at itsfully closed (down) position.

Remove cover tube from actuatorhandwheel, locate the down stopadjustment on the linear drive unitand with two spanners loosen thelock nut, run the lock nut andtubular down stop to the end of thethread.

Fig. 23 Down Stop 2 Spanners

5.5 IQM Modulating Actuators 5.6 IQML Linear Drive Unit 5.7 IQML Adjusting Linear Stroke


Turn the actuator handwheelclockwise, linear drive will movedown towards the valve spindle,couple linear drive to valve spindle.

Turn the tubular down stopclockwise into the actuator until itcomes to a mechanical stop. If thevalve must close onto its seat by“TORQUE ACTION” then back off(anti-clockwise) the down stop byone third of one turn (equivalent to1mm). Run the lock nut down ontothe tubular down stop and tightenwith two spanners. There is no “upstop” (open) on the linear driveunit, the mechanical stop in thevalve will give this position. Refitthe top cover tube to thehandwheel using PTFE tape toseal the thread.

The linear drive unit is pre-packedwith grease type Rocol MTS 1000,use this or an equivalent hightemperature bearing grease.

A grease nipple is situated in the

base of the actuator to enablelubrication of the lead screw.Periodically, depending on usageand temperature, apply two pumpsof a grease gun.

13

5.7 IQML Adjusting Linear Stroke


WARNING:Ensure all power supplies areisolated before removing actuator covers.Check that the supply voltageagrees with that stamped onactuator nameplate.A switch or circuit breaker must beincluded in the wiring installation ofthe actuator. The switch or circuitbreaker shall be mounted as closeto the actuator as possible andshall be marked to indicate that it isthe disconnecting device for thatparticular actuator. The actuatormust be protected with overcurrentprotection devices rated inaccordance with Rotork publicationNo E130E Electric motorperformance data for IQ typeactuators.

WARNING:Actuators for use on phase to phasevoltages greater than 600V a.c. mustnot be used on supply systems suchas floating, or earth-phase systems,where phase to earth voltages inexcess of 600V a.c. could exist.

A lug with a 6mm diameter hole iscast adjacent to the conduit entriesfor attachment of an externalearthing strap by a nut and bolt.An internal earth terminal is alsoprovided.

Using a 6mm allen key loosen the4 captive screws evenly. Do notattempt to lever off the cover with ascrewdriver as this will damage the“O” ring seal and may damage theflamepath on a certified unit.

Fig. 24

Actuators containing a Setting Toolfitted to the inside of the terminalcompartment cover are identifiedwith a self adhesive yellow label onthe outside of the terminalcompartment cover.

The wiring code card fixed in thecover is particular to each actuatorand must not be interchanged withany other actuator. If in doubt checkthe serial number on the code cardwith that of the actuator.

Fig. 25

A plastic bag in the terminalcompartment contains:Terminal screws and washers.Spare cover “O” ring seal.Wiring diagram.Instruction book.

Fig. 26

Only appropriate certified Explosionproof entry reducers, glands orconduit may be used in hazardouslocations.

Remove red plastic transit plugs.Make cable entries appropriate tothe cable type and size. Ensurethat threaded adaptors, cableglands or conduit are tight and fullywaterproof. Seal unused cableentries with a steel or brassthreaded plug. In hazardous areasan appropriately certified threadedblanking plug must be used.

Cable Connections6

6.3 Cable Entry

6.1 Earth/Ground Connections

14

6.2 Removing Terminal Cover


15

On EExde enclosure unitsconnections to the power andcontrol terminals must be madeusing AMP type 160292 ring tabsfor power and earth terminals andAMP type 34148 ring tabs for thecontroll terminals.

Refer to the wiring diagram insidethe terminal cover to identifyfunctions of terminals. Check thatsupply voltage is the same as thatmarked on the actuator nameplate.

Remove power terminal screen.

Begin by connecting these cablesand replace screen.

When all connections are madeensure wiring diagram is replaced

in the terminal compartment.Ensure cover “O” ring seal andspigot joint are in good conditionand lightly greased before re-fittingcover.

6.4 Connecting to Terminals 6.5 Replacing Terminal Cover


The Rotork IQ range of actuators isthe first that enablescommissioning to be carried outwithout removing covers aftercabling has been completed.

Setting torque, limit and otherfunctions is achieved by using theInfra-Red Setting Tool. The SettingTool is certified Intrinsically Safe toallow commissioning in hazardousareas with power on.

All the commissioning functions arestored in non-volatile memory inthe actuator. The Setting Toolenables the user to view all thefunctions in turn via the actuatordisplay window. As each function isviewed its setting can be checkedand, if required, changed within thebounds of that function.

The setting procedure is dividedinto two stages:

1. Primary FunctionsSettings for end of travel limit actions, torque values, limit positions etc.

2. Secondary FunctionsSettings covering the control, indication and optional equipment functions.

All IQ actuator functions areconfigured before dispatch toRotork standard default settingsunless alternatives have beenspecified with the order. Shoulddifficulty be encountered duringcommissioning the defaultsettings can be reinstated,returning the actuatorconfiguration to its originalmanufactured state. Sitecommissioning can then beginagain.(refer to section 9.15 page 59.)

The default function should beused with caution as settingsselected after manufacture may beessential for the safe operation ofthe valve and/or plant.

Actuator Display

NOTE: The Primary Functionsmust be commissioned first.

Position Display 50 This may be an open or closed symbol or a percentage open value.

Torque and Position Refer to Section 10 Monitoring

Password P? PC I r Ic

Setting Branch cr(crossroad)

16

Commissioning7

7.1 The Setting Procedure

Primary FunctionsDirection

Limit ActionsTorque ValuesLimit Positions

Secondary FunctionsIndication Contacts

Control ModeOptions

Help ScreensDefaults


SpecificationEnclosure IP67

Certification EEx ia IIC T4 (intrinsically safe).FM, INT SAFE, Class I & II Div 1 Groups A B C D E F G, T4ACSA, Exia, Class I, II Div 1 Groups A B C D

Power supply 9V Battery (supplied & fitted).

Operating range 0.75m (from actuator display window)

Name Instruction1. Key* Display next function down

2. Key* Display next function across

3. Key Decrease/change displayed function's value or option setting

4. Key Increase/change displayed function's value or option setting

5. Key Enter displayed value or option setting

* Pressing the two arrow keys together returns the actuator display to the position indication mode

Infra-red local operation (when enabled)5. Key Stop actuator

6. Key Open actuator

7. Key Close actuator

8. Infra-red Transmitter Window

Fig. 27 The Setting Tool

Setting Tool Battery ReplacementBattery status can be checked by looking at the Infra-red transmitter windowwhile depressing any Setting Tool button. A flashing red indicator should beseen.

Battery replacement must be carried out in a safe area. To replace thebattery remove the six caphead screws in the back of the Setting Tool.Remove the back cover to expose the battery.

In order to maintain hazardous area certification fit only Duracell MN1604 orRayovac Alkaline Maximum NoAL-9V battery types.

Refit cover ensuring red indicator LED faces the transmitter window in theback cover.

When a button is depressed the Setting Tool transmits the relevantinstruction to the actuator by infra-red pulses and must therefore be directlyin front of the actuator indicator window and at a distance no greater than0.75m.

17

6

428

7

5

3

1

7.2 The Setting Tool


With the actuator securely mountedon the valve, the mains supply onand Local control or Stop selected.

PRESS THE KEY

The actuator display will changeand the Torque + Position displaywill be seen.(For instantaneous torque + positionmonitoring, (refer to Section 10,Monitoring, page 62)

PRESS THE KEY

The actuator display will changeand the password protectiondisplay will be seen.

The Actuator Function SettingsCan Be Protected by the Use

of a Password.

To enable setting and adjustmentof the actuator functions the correctpassword must be entered. Thefactory set (default) password is[ld] . If the actuator has previouslybeen set with a site password thismust be displayed.

Use the or keys to scrollthrough the available passwords00–FF (hexadecimal). With thecorrect password displayed pressthe enter key.

PRESS THE KEY

Two “setting” bars will appear andwill remain visible on every functiondisplay screen.

Default Password,Setting Mode Enabled.

To configure a new password, theactuator must be in setting modewith the password display – settingmode enabled – showing,PRESS KEY. The display willchange to [PC] . Using the orkey scroll through the availablepasswords until the desiredpassword is displayed.

PRESS THE KEY

Password Changed to [IE]

NOTE: The new passwordbecomes effective the next timesetting mode is entered.

The actuator function settings canbe checked without entering thecorrect password. The settings canonly be viewed and not altered. Thesetting bars will not be seen.

Password Display, Checking Mode

Once the procedure has beenentered in the required mode

PRESS THE KEY.

The procedure branch [Cr](crossroad) display can now beseen.(refer to Section 7.7 page 19)

18

7.3 Entering the ActuatorSetting Procedure

7.6 Checking Mode7.4 Setting Mode – Password 7.5 New Password [PC]


To access the Primary Functionsettings press the arrow key .

(refer to Section 8 CommissioningPrimary Functions page 20.)

To access the Secondary Functionsettings press the arrow key .

(refer to Section 9 CommissioningSecondary Functions page 30)

Actuator functions as laid out in thePrimary and Secondarycommissioning stages, can beindividually displayed by using theSetting Tool arrow keys.

The arrow key will always displaythe FIRST function on the nextlevel DOWN within the procedure.

The arrow key will alwaysdisplay the NEXT function on theSAME level and will wrap aroundthe functions on the same level.

The actuator display indicatorlamps will continue to indicatevalve position.

Actuator functions are displayed incode form in the top portion of theliquid crystal display screen.

The setting for the displayedfunction is shown in the lowerportion of the screen. Dependingon the actuator function displayed,its setting may be an option or avalue. In setting mode the Setting

Tool or keys will cause thesetting to be changed. In checkingmode the settings cannot bealtered.

In setting mode, once displayed, anew setting can be entered into theactuator memory by pressingthe key . The setting will flash offand back on, confirming itsselection.

TOP PORTIONFunction e.g.tC = Torque Close

LOWER PORTIONFunction Setting e.g. Value = 40%

Typical Actuator Function DisplaySetting Mode Enabled.

There are four ways of returning tovalve position display:1. Approximately 5 minutes after

the last Setting Tool operation the display will automatically return to position display.

2. Press the and arrow keys together.

3. Press the arrow key until the display returns to position.

4. With any actuator function screen displayed, select Remotecontrol using the red Local/Stop/Remote selector.

19

7.7 Procedure Branch Crossroad [Cr]

7.8 The Actuator Display Setting/Checking Mode

7.9 Returning toValve Position Display


Fig. 28

The actuator’s Primary Functionsettings affect the correct operationof the valve by the actuator. If theactuator has been supplied withthe valve, the valve maker orsupplier may have already madethese settings.

ELECTRICAL OPERATION MUSTNOT TAKE PLACE UNTIL THEPRIMARY SETTINGS HAVEBEEN MADE AND CHECKED.

This instruction assumes settingmode has been entered.(refer to 7.4 page 18)

With the actuator mounted on thevalve, the power supply on andLocal or Stop control selected,point the Setting Tool at theactuator indicator window from adistance of no more than 0.75m.By pressing the key and whenappropriate, the key, it ispossible to move through theprocedure, displaying the various

functions and their settings asshown in Fig. 29, (refer to page21). The right-hand side of Fig. 29explains the function of each LCDdisplay.

Power Off SettingIQ allows settings to be viewedand set without main power. Toenable this function, engagehandwheel drive and rotate untilthe output drive moves by one turn(refer to page 3). The Setting Toolcan now be used, As long as aSetting Tool key press takes placewithin the 30 seconds timeoutperiod, Power Off Setting willremain enabled. If no infra-redSetting Tool communication takesplace the display will return toindicating position. The actuatormust then be operated byhandwheel to re-enable Power OffSetting.Settings and operation must beverified by electric operation andfunction test of the actuator toensure correct operation .

20

Commissioning Primary Functions

8

Viewing the PrimaryFunction Settings


Position Display(This may be an open or closed symbol or a % open value.)

Torque and Position Display

Password Password Change

Procedure Branch (crossroad)

Direction to Close Close Action Open Action

Torque Value Closing Torque Value Opening

Limit Closed Limit Open

Position Display

Fig. 29 Primary Setting Function Displays

Refer to section 7Commissioning Information

INDEX TO PRIMARY FUNCTIONSpage

C1 Direction to Close 22C2 Close Action 23C3 Open Action 24tC Torque Value Closing 25tO Torque Value Opening 26LC Set Limit Closed 27LO Set Limit Open 27

The actuator can be configured to be clockwise or anti-clockwise to close.

21

Viewing the Primary Function Settings

50

P? PC Ir Ic

Cr

C1 C2 C3

tC tO

LC LO

50

IrDA


Manually operate actuator and valveto establish correct closing direction.If the handwheel labelling is foundto be incorrect please apply toRotork for conversion labels.

Using the or key, displaycharacter conforming to correctclosing direction.

[C] in the Setting Field IndicatingClockwise to Close.

[A] in the Setting Field IndicatingAnti-clockwise to Close.

Having ensured that the displaycorresponds to the establishedclosing direction

PRESS THE KEY.

The displayed option will flash,indicating that it has been set.

PRESS THE KEY.

22

Direction to CloseC1

50

P? PC Ir Ic

Cr

C1 C2 C3

tC tO

LC LO

50


The actuator can be configured toclose on torque for seating valvesand limit for non-seating valves.

Refer to valve manufacturer forrecommended selection

In the absence of valvemakerinstructions refer to the followingtable

Valve type Close Open

Wedge gate “torque” “limit”Globe “torque” “limit”

Butterfly “limit” “limit”Thru conduit “limit” “limit”Ball “limit” “limit”Plug “limit” “limit”Sluice gate “limit” “limit”Penstock “limit” “limit”Parallel slide “limit” “limit”

Using the or key, display thedesired option.

[Ct] in the Setting Field IndicatingClose on Torque.

[CL] in the Setting Field IndicatingClose on Limit.

Having selected the required option

PRESS THE KEY.


PRESS THE KEY.

NOTE: When set to close ontorque, the actuator will apply thevalue of torque as set for [tC] inseating the valve.(refer to [tC] page 25.)

23

50

P? PC Ir Ic

Cr

C1 C2 C3

tC tO

LC LO

50

Close ActionC2


The actuator can be configured toopen on torque for back seatingvalves or limit for non back seatingvalves. Refer to valve manufacturerfor recommended setting. In theabsence of valvemaker instructionsset “Open Limit” .

Using the or key display thedesired option.

[Ot] in the Setting Field IndicatesOpen on Torque.

[OL] in the Setting Field IndicatesOpen on Limit.

PRESS THE KEY.


PRESS THE KEY.

NOTE: When set to open ontorque, the actuator will apply thevalue of torque as set for [tO] inback seating the valve.(refer to [tO] page 26)

24

Open ActionC3

50

P? PC Ir Ic

Cr

C1 C2 C3

tC tO

LC LO

50


The value of torque available in theclose direction can be configured.Refer to valve manufacturer forrecommended value.The closing torque value can bevaried between 40% and Rated, in1% increments.

Using the and keys displayrecommended value.In the absence of a recommendedtorque value, try a low setting andincrease until satisfactory valveoperation is achieved.

PRESS THE KEY.

The displayed value will flash,indicating that it has been set.

Should the set value of torque bedeveloped in closing, the actuatorwill torque trip and stop.

PRESS THE KEY.

NOTE: Rated torque is quoted onthe actuator nameplate.

40% of Rated Torque

99% of Rated Torque

Rated Torque

25

Torque Value ClosingtC

50

P? PC Ir Ic

Cr

C1 C2 C3

tC tO

LC LO

50


26

The value of torque available in theopen direction can be configured.Refer to valve manufacturer forrecommended value.

The opening torque value can bevaried between 40% and Rated, in1% increments. In addition “Boost”can be configured when no opentorque protection is required.

BOOST SHOULD NOT BESELECTED WHEN THEACTUATOR HAS BEENCONFIGURED TO OPEN ONTORQUE (refer to [C3] page 24)unless back seating at Ratedtorque is acceptable.

Using the and keys display therecommended torque value.

In the absence of a recommendedtorque value, try a low setting andincrease until satisfactory valveoperation is achieved.

NOTE: Rated torque is quoted onthe actuator nameplate. Boosttorque is at least 140% of Ratedtorque.

PRESS THE KEY.

The displayed value will flash,indicating that it has been set.

Should the set value of torque bedeveloped in opening, the actuatorwill torque trip and stop.

PRESS THE KEY.

40%

99%

Rated

Boost

In checking mode, on pressing the key after reviewing open torque

setting, the display will revert tovalve position.

Torque Value OpeningtO

50

P? PC Ir Ic

Cr

C1 C2 C3

tC tO

LC LO

50


27

NOTE: It is possible to set theOpen Limit Position [LO] first.

NOTE: When in checking mode SetLimit Closed [LC] does not appear.

With [LC] displayed

Limit Closed

Move valve manually to the closedposition. Allow for overrun bywinding actuator output open up toone turn.

PRESS THE KEY.

The two bars will flash and theclosed indicator lamp willilluminate, indicating closed limitposition has been set.

PRESS THE KEY.

To check closed limit position handwind valve open one turn, whenamber lamp should illuminate andthe closed lamp should extinguish.Wind valve back closed one turn,when closed lamp should illuminatewith the amber lamp extinguished.

Set Limit ClosedLC

Set Limit OpenLO

NOTE: When in checking mode SetLimit Open [LO] does not appear.

With [LO] displayed

Limit Open

Move valve manually to the openposition. Allow for overrun bywinding actuator output closed upto one turn.

PRESS THE KEY.

The two bars will flash and theopen indicator lamp will illuminate,indicating open limit position hasbeen set.

PRESS THE KEY.

The open symbol (refer to Fig. 4.1.page 4) should now appear.

50

P? PC Ir Ic

Cr

C1 C2 C3

tC tO

LC LO

50

50

P? PC Ir Ic

Cr

C1 C2 C3

tC tO

LC LO

50


If the procedure has been followedas described, the positional displaywill indicate that the actuator is inthe open position.

Select Remote control momentarily,using the red selector to exitsetting procedure and then selectrequired control: Local, Stop orRemote.

With the correct settings madeelectric operation can now becarried out safely.

28

50

P? PC Ir Ic

Cr

C1 C2 C3

tC tO

LC LO

50

Return toPositional Display


29

PrimaryFunctions

50 Positional Display

IrDAComms

Contact S1

Contact S2

Contact S3

Contact S4

Control ModeConfiguration

Contact Function Value Contact Form

CellPhone

P? PC Ir

r1

A1 A2 A3 A4 A5 A6 A7 A8 A9

r2 r2

r3

r4 r4 r4

r3 r3

r2

r1 r1

Ic

cr

ESD ActionESD

Contact Type

Extra IndicationContacts CPT

FolomaticRemote Control

Remote Control Source

BusSystem

InterrupterTimer

Setting ToolLocal Control

Power LossInhibit

ESD ThermostatBy-pass

ESD OverrideLocal Stop

2-wireControl

ExternalInterlocks

ConditionalControl

MaintainedLocal Control

ESD OverrideInterlocks

OE

- If OE, OF, OP, or OJ are fitted and selected “ON” their appropriate set-up screens will be inserted here.

OI OF Od OP OJ Or OSOption Selection

Option Functions

Help Screens

Default Option

H1

d1 d2

H2 H3 H4 H5 H6 H7 H8 H9

Return to Positional Display Fig. 30 Secondary Functions


Administrator

Peter says can we print annotations

Commissioning Secondary Functions

9 Accessing the Secondary Functions

9.1

Having established that thePrimary Functions have beencorrectly set, the SecondaryFunctions can now be configuredto suit site control and indicationrequirements.

It is possible to move through thevarious Secondary Functions asshown in Fig. 30 using the and

keys.

The actuator wiring diagram willindicate any options fitted.

Options Setting Tool Local Control[Or] and Power Loss Inhibit [OS]are standard features their usebeing optional.

In order to display the SecondaryFunctions it is necessary to pressthe key until [Cr] appears.

If you have chosen to enterSecondary Functions in thechecking mode the display will beas Fig. 31.

If you have chosen to enterSecondary Functions in the settingmode the display will be asFig. 32 (refer to Section 7.)

Fig. 31 Fig. 32

PRESS THE KEY.

SECONDARY FUNCTION INDEXpage

9.1 Accessing the Secondary Settings 309.2 Indication Contacts S1, S2, S3 and S4 319.3 Control Mode Configuration 339.4 Option Extra Indication Contacts S5 - S8 369.5 Option CPT (Current Position Transmitter) 379.6 Option Folomatic Remote Control 389.7 Remote Control Source 419.8 Option Pakscan 429.9 Option Modbus 469.10 Option Profibus DP 509.11 Bus Systems Positioning Control Settings 549.12 Option Interrupter Timer 569.13 Setting Tool Local Control 589.14 Power Loss Inhibit 589.15 Default Options 5910.1 Help Screens 6310.2 IrDA Diagnostics and Configuration 68

30


Indication contacts S1 [r1], S2[r2], S3 [r3], and S4 [r4] mayeach be set to trip for any one ofthe following functions:-

Code Function[CL] closed end position[OP] open end position[Po] intermediate position[tC] torque trip close[tO] torque trip open[tt] torque trip any position[t l] torque trip mid travel[dC] actuator closing[dO] actuator opening[d?] actuator rotating[St] motor stalled[bA] battery low[HA] hand operation[bL] blinker[LS] local stop[Ol] open interlock[Cl] close interlock[lL] interlock active[ES] ESD signal[LP] lost phase[Lo] local selected[rE] remote selected

[Fd] actuator failure[24] 24V power failure[rr ] motor running[oo] 3-phase supply good[Ht] thermostat tripped[An] "or" function[rP] relay parity

The S contact form can be setnormally open [nO] or normallyclosed [nC].

The procedures for setting upcontacts S2, S3 and S4 are thesame as those shown for S1.

Using the or key display thedesired function.

PRESS THE KEY.

The displayed function will flashindicating that it has been set.

Contact S1 Configuredto Trip at Valve Closed Limit.

PRESS THE KEY.

When the S contact function is setto [Po], the required intermediateposition value must be set.No other contact functionrequires a value to be set.

The value can be set from 1%open to 99% open in 1%increments.

Using the or key, display therequired value.

PRESS THE KEY.

The displayed value will flashindicating that it has been set.

Value Set to Indicate25% Open

PRESS THE KEY.

31

Indication ContactsS1 S2 S3 and S4

9.2Contact S1 – Function

r1Contact S1 – Value

r1


32

Contact S1Contact Form

r1

Use the or keys to selectbetween [nO] (normally open) and[nC] (normally closed).

PRESS THE KEY.

The displayed option will flashindicating that it has been set.

Contact S1 Configured as aNormally Open Contact

NOTE: If function [Po] is selectedand it is configured as a normallyopen contact it will make at the setvalue with the actuator moving inthe open direction.

To access S2–S4

PRESS THE KEY.


The control mode configurationaffects how the actuator willrespond under conditions ofemergency shut down, localcontrol, remote control interlocks,and 2-wire remote control. Unlessspecified with order, the controlmode configuration will be set asshown for default configuration(refer to page 59)

If it is necessary to change theconfiguration follow the instructionsin this section.

There are 9 configurable controlfunctions:

A1 ESD ActionA2 ESD Contact TypeA3 ESD Thermostat By-passA4 ESD Override Interlock A5 ESD Override Local Stop A6 Self-maintained Local ControlA7 2-wire ControlA8 External InterlocksA9 Conditional Control

An active ESD signal applied to theactuator will override any existingor applied local or remote controlsignal. ESD can be configured tooverride the motor thermostat,active interlocks or local Stopselection. Refer to A3, A4 and A5

The default action under an activeESD signal is Stay put to [SP]

Press the or key to select therequired ESD action:[CL] Close on ESD[SP] Stay put on ESD[OP] Open on ESD

PRESS THE KEYThe displayed option will flashindicating that it has been set.

ESD Set to Stay Put

The default setting for ESD contacttype is [nO].The actuator responds to a remotecontrol ESD signal derived from anormally open contact making.For ESD, where a remote controlESD signal is derived from anormally closed contact breaking,the signal being removed, press the or key.

The display will change to [nC]PRESS THE KEY


Actuator Responds to a RemoteNormally Open

ESD Contact Making

NOTE: If Folomatic analoguecontrol is required A2 must be setto [nO]

The default value for motorthermostat by-pass is disabled[OF] during ESD. The thermostatsremain active during ESD.

If the motor thermostats arerequired to be by-passed duringESD, (thermostats inactive),Press the or key to display[On]

WARNING: Actuator hazardousarea certification is invalidatedwhile the thermostats areby-passed.


Thermostat By-pass Disabled

33

Control ModeConfiguration

9.3ESD Action

A1ESD Contact Type

A2 ESD Thermostat `````` By-passA3


ESD OverrideInterlocks

The default setting for ESDoverride interlocks is [OF] . ESDaction will not override an activeinterlock applied to the actuator.

If an applied ESD signal is requiredto override active interlockscausing the ESD action as set forA1, press the or key. Thedisplay will change to [On]

PRESS THE KEY


ESD Override Interlock - Off

The default setting for ESDoverride local Stop is [OF] . ESDwill not override an active localStop.

If an applied ESD signal is requiredto override local Stop causing theESD action as set for A1, press the

or key. The display willchange to [On]

PRESS THE KEY


ESD Override Local Stop - Off

The default setting for localactuator pushbutton control ismaintained [On].

If non-maintained actuatorpushbutton control is required(jogging, inching, push to run),press the or key. The displaywill change to [OF]

PRESS THE KEY


Self-maintained Local Control

The default setting for 2-wireremote control is open priority[OP] . When the external contactmakes the actuator will open.

When the external contact breaks,or the signal is lost, the actuatorwill close. Refer to actuator wiringdiagram or publication E120E.

Use the or key to select therequired priority:[OP] Open[SP] Stay put [CL] Close

PRESS THE KEY


2-wire Control - Open Priority

34

ESD OverrideLocal Stop

A52-wire Control

A7MaintainedLocal Control

A6A4


Actuators are delivered with theinterlock facility disabled [OF].Refer to the actuator wiringdiagram or publication E120E forinterlock control circuits.

To enable remote externalinterlocks press the or key

The display will change to [On]

PRESS THE KEY


Interlocks Disabled

NOTE: If interlocking is required inonly one direction, it will benecessary to connect a linkbetween the actuator terminalsassociated with the other direction.

Where a high level of safetyintegrity is required, ConditionalControl can be configured.

In this mode two discreet signalsare required for remote operation.Remote control will be conditionalon both a control signal (open orclose) and the appropriateinterlock signal being appliedsimultaneously. Failure of either ora spurious signal will not causeoperation.

Interlocks [A8] must be set [On].Interlock signals are not requiredfor local operation.

The default setting for conditionalcontrol is [OF] .

Conditional Control Off

To enable conditional control pressthe or key.

The display will change to [On]

PRESS THE KEY


35

External InterlocksA8

Conditional ControlA9


Display Extra ContactSet-up Screens

Extra indication contacts S5 [r5],S6 [r6], S7 [r7] and S8 [r8] areavailable as an option.

Check actuator circuit diagram forinclusion.

When the Extra Contact Option isincluded the set-up procedure andavailable contact functions forS5 - S8 are identical to S1 - S4(refer to section 9.2 page 31)

Unless specified with order thedefault setting for the extraindication contacts will be asfollows:

S5 [r5] Close limit indicationS6 [r6] Open limit indicationS7 [r7] Torque trip mid travelS8 [r8] Remote control selected

NOTE: If the Extra Contact Optionis not included in the actuatorbuild, any settings made forS5 - S8 will have no effect on theindication output of the actuator.

The action of turning on the ExtraContact Option makes anadditional series of set-up screensavailable

Enabled DisabledExtra Contact Set-up Displays

Press the or key to select theExtra Contact Option set-upscreens [On]

PRESS THE KEY


PRESS THE KEY TO ACCESSS5 TO S8 SET-UP DISPLAYS.

The procedure for setting S5 toS8 is the same as that for S1 toS4. (refer to section 9.2 page 31)

36

OEOption - Extra Indication Contacts

9.4


Setting instructions for actuatorsincluding a CPT providing 4-20 mA analogue positionfeedback.

The CPT is an optional extra. It maybe internally or externally powered.

Check wiring diagram for inclusionand connection details.

With [HI] Displayed, the (CPT)20mA Output will Correspond to

Actuator Fully Open.

If 20mA is required to correspond toactuator closed use the or keyto change to [LO].

PRESS THE KEY.

The displayed option will flashindicating that the option has beenset.

NOTE: If the actuator has optionsFolomatic and CPT, redefining theCPT, will require the Folomatic to berecommissioned.

(refer to section 9.6 Folomatic [OI]page 38)

37

Option - CPT [Ol](Current Position Transmitter)

9.5


Setting instructions for actuatorsincluding a Folomatic(proportional) Controller for usein (analogue) valve positioncontrol.

The Folomatic is an optionalcontrol device. Check actuatorwiring diagram for inclusion.

Before setting the parametersfor Option Folomatic ensureRemote Control Source [bO] hasbeen selected in Section 9.7 [Od](refer to page 41).Folomatic set-up screens can beturned OFF to provide extrasecurity.

Once selected ON the optionfunction displays allowcommissioning of the Folomatic tobe undertaken.

NOTE: Turning ON/OFF theFolomatic set-up screens (whenfitted) does not affect its operation.

This instruction lists the Folomaticfunction displays in their sequenceand assumes that all Folomaticfunctions are to be checked/set.

The actuator should be selected inLocal or Stop with the set pointsignal connected to terminals26(+) and 27(-) (refer to wiringdiagram).

Before commissioning of theFolomatic functions can begin, theFolomatic Feedback must be set tosuit the applied set point signal.PRESS THE KEY UNTIL [OI]IS DISPLAYED

With [HI] displayed, an increasingset point signal will correspond tovalve opening.

If a high set point signal is requiredto correspond to valve closing usethe or key to change to [LO].

PRESS THE KEY.

The displayed option will flash indicating that it has been set.If setting [OI] is modified aftercommissioning the Folomatic, it willbe necessary to recommission theFolomatic.

Press the key to access theFolomatic set-up display [OF] .

The action of turning on theFolomatic option makes anadditional series of settingsavailable.

Folomatic Folomatic Set-up Screens Set-up Screens

OFF ON

Use the or key to selectFolomatic Display [On].

PRESS THE KEY.

The displayed option will flash indicating that it has been set.

Press the key to access theFolomatic set-up displays.

38

Option - FolomaticRemote Control

9.6 Display FolomaticSet-up Screens

OFFolomatic Feedback

Ol


Using the or key select [ l] forcurrent set point signal or [ U] forvoltage set point signal.

Current Mode Selected

PRESS THE KEY.


Press the key to display [Fr].

Using the or key select [05] ,[10] or [20] to correspond with theset point signals within the range of0–5mA or volts, 0–10mA or volts or0–20mA or volts (i.e. 4–20mA).

0–20mA or VoltageRange Selected

PRESS THE KEY.


Press the key to display [FL] .

APPLY MINIMUM SET POINT SIGNAL

Using the or key select:[ ][ ] = valve closed [01] to [99] = percent open [ ] = valve open to correspond with the LOWset point signal.

Valve Closedon LOW Signal

PRESS THE KEY.

The displayed value will flashindicating that it has been set.

Press the key to display [FH] .

APPLY MAXIMUM SET POINT SIGNAL

Using the or key select:[ ][ ] = valve closed[01] to [99] = percent open [ ] = valve open to correspond with the HIGH setpoint signal.

Valve Openon HIGH Signal

PRESS THE KEY.

The displayed value will flash indicating that it has been set.

Press the key to display [Fd] .

39

Valve PositionLOW Set Point

FL Valve PositionHIGH Set Point

FHSet PointSignal Range

FrSet PointSignal Type

Fl


The motion inhibit timer introducesa delay in the actuator response toa rapidly fluctuating set point signal,preventing unnecessary movement.

Once the system stabilises theactuator will respond to steadychanges in the set point signal asnecessary.

Use or key to adjust motion inhibit time in seconds: range 0–99.Normally it is recommended thatmotion inhibit time should not beset to less than 5 seconds.(refer to note on page 58)

Motion inhibittime set to 5 seconds

PRESS THE KEY.


Press the to display [FA] .

Use or key to enable [On] ordisable [OF] action on loss of setpoint signal.

[On] – Failsafe as determinedby [FF] .

[OF] – Failsafe to position corresponding to low setpoint.

Enabled

PRESS THE KEY.


NOTE: Failsafe action “ON” will beeffective only for systems using anoffset or live zero signal range, forexample 4–20 mA.

Press the to display [FF] .

Failsafe action when [FA] enabled.

Use or key to select, on loss ofset point signal:

[Lo] – move valve to positioncorresponding to minimumset point.

[SP] – stayput on loss of set point.[Hl] – move valve to position

corresponding to maximumset point.

PRESS THE KEY.


Commissioning of the Folomatic isnow complete. Remote control maybe selected.

If the actuator hunts or respondsunnecessarily to a fluctuating setpoint signal the deadband must beincreased. If more accurate controlis required the deadband may bedecreased.

Use the or key to select thedeadband width. Range 00–99corresponds to 0–9.9% of setpointsignal.

NOTE: Maximum deadband is 9.9%of valve stroke. Normally minimumdeadband should not be less than 1%.

Deadband Set to 1.2%of Valve Stroke

PRESS THE KEY.


Press the key to display [Ft] .

40

Motion Inhibit Timer Adjustment

FtFailsafe Action

FFAction On Loss ofSet Point Signal

FADeadband Adjustment

Fd


The available forms of remotecontrol are listed below:

Standard hardwired controlAnalogue control-Option FolomaticNetwork control including

Option Pakscan Option ModbusOption Profibus

The setting for Remote ControlSource will depend on the type ofremote control required and theoption specified and fitted. Checkactuator circuit diagram for remotecontrol form.

The setting of Remote ControlSource will be determined by theoption that has been fitted, if any.

[rE] Standard hardwired remotecontrol or Option Modbus

[bO] Option Folomatic

[OP] Options Pakscan, Profibus orFoundation Fieldbus

[OF] All remote control disabled(Actuator available for localcontrol only).

To change the remote sourcepress the or key until therequired setting is displayed.

PRESS THE KEY.The displayed option will flashindicating that it has been set.

Standard Hardwired RemoteControl.

41

Remote Control Source9.7

Remote Control SourceOd


Bus SystemOption Pakscan [OP]

42

Setting instructions for actuatorsincluding an optional Pakscan FieldControl Unit - check wiring diagramfor inclusion.

Before setting the parametersfor Option Pakscan ensureRemote Control Source [OP] hasbeen selected in Section 9.7 [Od](refer to page 41).

Pakscan set-up screens can beturned off to provide extra security.The action of turning screens on oroff does not affect its operation.

Use the or key to turn onPakscan set-up screens.

Pakscan Set-up Screens ON

PRESS THE KEY


Press the key to display thePakscan set-up screens.

The actuator Pakscan Field ControlUnit must be allocated a uniqueloop address.

The actuator must be in“Loopback” for its address to be setor changed. Loopback can beachieved in two ways:

1. Turn OFF the master station.

2. Disconnect the actuator from the 2-wire control loop.

Using the or keys display therequired loop address.

Address to be set within the range01–F0 Hexadecimal. (refer to tableon page 71)

PRESS THE KEY.


Press the key to display [Pb] .

The actuator Pakscan Field ControlUnit must be set up with the loopbaud rate. For a Pakscan 2-wirecontrol loop the selected baud ratemust be common to the masterstation and all the field control unitsincluded in the loop.

The actuator must be in“Loopback” for its baud rate to beset or changed.

Loopback can be achieved in twoways:

1. Turn OFF the master station.

2. Disconnect the actuator from the2-wire control loop.

Continued

9.8Pakscan Address

PAPakscan Baud Rate

Pb


Using the or keys display therequired baud rate.

01 = 110 baud 03 = 300 baud 06 = 600 baud 12 = 1200 baud 24 = 2400 baud

2400 baud rate set

PRESS THE KEY.

The displayed option will flash indicating that it has been set.Press the key to display [PF]

The IQ actuator has the facility to accept 4 auxiliary inputs (AUX1 - AUX4).These are used when supplementary remote control or digital auxiliary inputsare required in addition to the standard control and feedback featuresincorporated into the Pakscan card. It is also possible to have a combinationof both remote control and volt free inputs to provide, for example, open andclose control as well as a high and low tank level alarm indication, supplied viaan external transducer.The hexadecimal number displayed under PF can be considered as a"software mask". It is this mask that tells the Pakscan card what type of inputto expect, control or input signal, and what form the input will be, normallyopen or normally closed.(refer to page 71 for Binary, Hexadecimal andDecimal Conversion Table.)To decipher the mask the number needs to be split into two separatehexadecimal characters, each of which can be sub-divided into 4 binary bits.The first 4 bits represent the function and the second 4 represent the inputsource (known as invert). Pictorially this can be represented as:

Left side hex character Right side hex characterAux 4 to 1 (function) AUX 4 to 1 (Invert)

Bits 4 3 2 1 4 3 2 1When used for remote control of the actuator bits 4 to 1 of the functioncharacter have been designated as follows:Bit 4 (AUX4) - ESDBit 3 (AUX3) - Stop/Maintain Bit 2 (AUX2) - CloseBit 1 (AUX1) - Open(When used for digital signal inputs they are simply designated as AUX 4 to AUX 1)

43

Pakscan Baud RatePb Pakscan Remote

Auxiliary InputPF


Rules

1. Function bit set to "0"Any function bit set to "0" indicates that the particular aux input is to be treatedas a digital signal for field status reporting, e.g. a level switch or motor runningstatus.

If the corresponding invert bit is set to a "0", an open contact is reported as alogic "1" and a closed contact is reported as a logic "0". (i.e. this will invertthe input).

If the corresponding invert bit is set to a "1", an open contact is reported as alogic "0" and a closed contact is reported as a logic "1". (i.e. this gives a non-inverting input)

2. Function bit set to "1"Any function bit set to "1" indicates that the particular aux input is to be treatedas a digital command to operate the actuator.

When the corresponding invert bit is set to a "0" this represents an N.C.contact as being the command source, i.e. a closing contact de-energises theinput and an opening contact energises the input.

When the corresponding invert bit is set to a "1", this represents an N.O.contact as being the command source, i.e. a closing contact energises theinput and an opening contact de-energises the input.

3. ESD ControlWhen using ESD (aux input 4), the ESD contact mode setting [A2] should beset to the default value of [nO]. The [A1 ] - ESD direction setting should beset to either Open or Close the valve. (refer to page 33)

4. Stop/Maintain ControlWhen energised this will make the Aux input Open/Close/ESD control push-to-run, (non-maintained).

When de-energised, the Aux input Open/Close/ESD control will be maintained.

5. Remote I/P SettingEnsure that the correct [Od] setting is selected (refer to page 41).For Pakscan this is [OP]

The factory default for [PF] is [OF]

Examples1. The full range of remote controls is needed. Open and Close are NO andESD and Stop/maintain is NC

Aux I/P 4 3 2 1Function 1 1 1 1 = F Invert 0 0 1 1 = 3 i.e. set [PF] to [F3]

2. Open and close control is required along with 2 inverted digital signalinputs. (Note that with this setting the open and close commands will bemaintained)

Aux I/P 4 3 2 1Function 0 0 1 1 = 3 Invert 0 0 1 1 = 3 i.e. set [PF] to [33]

3. Only an ESD input is needed. The requirement is for push to run controlwith a NO contact input

Aux I/P 4 3 2 1Function 1 1 0 0 = CInvert 0 0 0 0 = 0 i.e. set [PF] to [C0]

44

Pakscan RemoteAuxiliary Input

PF


45

Using the or keys display therequired mask setting.

Auxiliary Input Mask [OF]

PRESS THE KEY


If Pakscan positioning control isrequired, return to the positiondisplay by pressing and keystogether.

Display [OF] (refer to page 54)

Setting [PP] is not used byPakscan. Entered settings willbe ignored

Pakscan RemoteAuxiliary Input

PF PP


Bus SystemOption Modbus [OP]

Setting instructions for actuatorsincluding an optional Modbus RTUmodule - check wiring diagram forinclusion.

Before setting the parametersfor Option Modbus ensureRemote Control Source [ rE] hasbeen selected in Section 9.7 [Od](refer to page 41).

Modbus module set-up screenscan be turned off to provide extrasecurity. The action of turningscreens on or off does not affect itsoperation.

Use the or keys to turn onModbus set-up screens.

Modbus Set-up Screens [On]

PRESS THE KEY


Press the key to display the Modbus set-up screens.

The Modbus module must beallocated a unique address.

To set the address the Modbusmodule must be isolated from thehost by disconnecting the RS485highway or turning off the hostdevice.

Using the or Keys display therequired address.

Address to be set within the range01 to F7 Hexadecimal, (refer topage 71 for conversion). If anaddress value outside this range isentered, the address set will revertto 01 (for 00) or F7 (for valueabove F7).

PRESS THE KEY

The displayed option will flashindicating that it has been set.Press the to display [Pb]

The Modbus module must be setto the RS485 highway baudrate.To set the baudrate the Modbusmodule must be isolated from thehost by disconnecting the RS485highway or turning off the hostdevice.

Using the or Keys display therequired baudrate:

[01] 110 [03] 300 [06] 600 [12] 1200 [24] 2400 [48] 4800 [96] 9600 [19] 19200 [38] 38400

2400 Baud

PRESS THE KEY


Press the to display [PF]

46

Modbus BaudratePb

Modbus AddressPA9.9


47

The IQ actuator has the facility to accept 4 auxiliary inputs (AUX1 - AUX4).These are used when supplementary remote control or digital auxiliary inputsare required in addition to the standard control and feedback featuresincorporated into the Modbus module. It is also possible to have acombination of both remote control and volt free inputs to provide, for example,open and close control as well as a high and low tank level alarm indication,supplied via an external transducer.

The hexadecimal number displayed under PF can be considered as a"software mask". It is this mask that tells the Modbus module what type ofinput to expect, control or input signal, and what form the input will be,normally open or normally closed. (refer to page 71 for Binary, Hexadecimaland Decimal Conversion Table.)

To decipher the mask the number needs to be split into two separatehexadecimal characters, each of which can be sub-divided into 4 binary bits.The first 4 bits represent the function and the second 4 represent the inputsource (known as invert). Pictorially this can be represented as:


Bits 4 3 2 1 4 3 2 1When used for remote control of the actuator bits 4 to 1 of the functioncharacter have been designated as follows:

Bit 4 (AUX4) - ESDBit 3 (AUX3) - Stop/Maintain Bit 2 (AUX2) - CloseBit 1 (AUX1) - Open

(When used for digital signal inputs they are simply designated asAUX 4 to AUX 1)

Rules


If the corresponding invert bit is set to a "0", an open contact is reported as alogic "1" and a closed contact is reported as a logic "0". (i.e. this will invertthe input)


2. Function bit set to "1"Any function bit set to "1" indicates that the particular aux input is to betreated as a digital command to operate the actuator.

When the corresponding invert bit is set to a "0" this represents an N.C.contact as being the command source, i.e. a closing contact de-energisesthe input and an opening contact energises the input.


3. ESD ControlWhen using ESD (aux input 4), the ESD contact mode setting [A2] should beset to the default value of [nO]. The [A1] - ESD direction setting should beset to either Open or Close the valve. (refer to page 33)

Modbus RemoteAuxiliary Input

PF


48

4. Stop/Maintain ControlWhen energised this will make the Aux input Open/Close control push-to-run.When de-energised, the Aux input Open/Close control will be maintained.ESD is always push to run (non maintained).

5. Remote I/P SettingEnsure that the correct [Od] setting is selected (refer to page 41).For Modbus this is [rE]



Aux I/P 4 3 2 1Function 1 1 1 1 = FInvert 0 0 1 1 = 3 i.e. set [PF] to [F3]

2. Open and close control is required along with 2 inverted digital signalinputs. (Note that with this setting the open and close commands will bemaintained)





Auxiliary Input Mask [OF]

PRESS THE KEY


Press the to display [PP]

Where Modbus parity bit detectionis used the module must be setwith the parity bit setting of thehost.

Using the or Keys display therequired parity bit:[no] No parity bit[En] Even parity bit[Od] Odd parity bit

No Parity Bit

PRESS THE KEY


continued

Modbus ParityPPModbus Remote

Auxiliary InputPF


49

For Modbus module positioningsettings and action on loss of signalsetting [OF] (refer to page 54)

If Modbus positioning control andaction on loss of communicationare required, return to theposition display by pressingand keys together.

Display [OF] (refer to page 54)


Bus SystemOption Profibus DP [OP]

50

Setting instructions for actuatorsincluding an optional Profibus DPmodule - check wiring diagram forinclusion.

Before setting the parametersfor Option Profibus ensureRemote Control Source [OP] hasbeen selected in Section 9.7 [Od](refer to page 41).

Profibus module set-up screenscan be turned off to provide extrasecurity. The action of turningscreens on or off does not affect itsoperation.

Use the or keys to turn onProfibus set-up screens.

Profibus set-up screens [On]

PRESS THE KEY


Press the key to display theProfibus set-up screens.

The Profibus DP module must beallocated a unique address.

To set the address the Profibusmodule must be isolated from thehost by disconnecting the RS485highway or turning off the hostdevice.

Using the or keys display therequired address.

Address to be set within the range01 to 7E Hexadecimal (refer topage 71 for conversion). If anaddress value outside this range isentered, the address set willrevert to 01 (for 00) or7E (for value above 7E).


Press the to display [Pb]

Profibus Address9.10 PA


Profibus RemoteAuxiliary Input

Proflags 2 setting determines theport used for communication andwhether the host has the ability tochange the Profibus moduleaddress.

Using the or keys display therequired setting:

Set: Port Host address change[01] 2 disabled[03] 1 disabled[06] 2 enabled[12] 1 enabled

The default setting is [12] . Onfailure to establish communicationthe setting will cycle between [12]and [06] at 4¼-minute intervalsuntil communication is established.

Port 1, Host Enabled


The power to the actuator mustnow be cycled in order for theProflags 2 setting to take effect.

Press the key to display [PF]

The IQ actuator has the facility to accept 4 auxiliary inputs (AUX1 - AUX4).These are used when supplementary remote control or digital auxiliary inputs arerequired in addition to the standard control and feedback features incorporated intothe Profibus module. It is also possible to have a combination of both remotecontrol and volt free inputs to provide, for example, open and close control as wellas a high and low tank level alarm indication, supplied via an external transducer.

The hexadecimal number displayed under PF can be considered as a "softwaremask". It is this mask that tells the Profibus module what type of input to expect,control or input signal, and what form the input will be, normally open or normallyclosed. (refer to page 71 for Binary, Hexadecimal and Decimal Conversion Table.)

To decipher the mask the number needs to be split into two separate hexadecimalcharacters, each of which can be sub-divided into 4 binary bits. The first 4 bitsrepresent the function and the second 4 represent the input source (known asinvert). Pictorially this can be represented as:


Bits 4 3 2 1 4 3 2 1

When used for remote control of the actuator bits 4 to 1 of the function characterhave been designated as follows:

Bit 4 (AUX4) - ESDBit 3 (AUX3) - Stop/Maintain Bit 2 (AUX2) - CloseBit 1 (AUX1) - Open

(When used for digital signal inputs they are simply designated asAUX 4 to AUX 1)

PFProfibus Proflags 2

Pb

51


52

Rules


If the corresponding invert bit is set to a "0", an open contact is reported as alogic "1" and a closed contact is reported as a logic "0". (i.e. this will invertthe input)


2. Function bit set to "1"Any function bit set to "1" indicates that the particular aux input is to be treatedas a digital command to operate the actuator.

When the corresponding invert bit is set to a "0" this represents an N.C.contact as being the command source, i.e. a closing contact de-energises theinput and an opening contact energises the input.


3. ESD ControlWhen using ESD (aux input 4), the ESD contact mode setting [A2] should beset to the default value of [nO]. The [A1] - ESD direction setting should beset to either open or close the valve. (refer to page 33)

4. Stop/Maintain ControlWhen energised this will make the Aux input Open/Close control push to runWhen de-energised, the Aux input Open/Close control will be maintained.ESD is always push to run (non maintained).

5. Remote Source Setting [Od]Ensure that the correct [Od] setting is selected (refer to page 41).

For Profibus this is [OP]



Aux I/P 4 3 2 1Function 1 1 1 1 = F Invert 0 0 1 1 = 3 i.e. set [PF] to [F3]

2. Open and close control is required along with 2 inverted digital signal inputs.(Note that with this setting the open and close commands will be maintained)



Aux I/P 4 3 2 1Function 1 0 0 0 = 8Invert 0 0 0 0 = 0 i.e. set [PF] to [80]

Profibus RemoteAuxiliary Input

PF


53


Auxiliary input mask OF

PRESS THE KEY


If Profibus positioning control andaction on loss of communicationare required, return to the positiondisplay by pressing

and keys together.Display [OF] (refer to page 54)

Setting [PP] is not used byProfibus. Entered settings willbe ignored

PPProfibus RemoteAuxiliary Input

PF


If the system control strategy forPakscan, Modbus or Profibusrequires intermediate valve travelpositioning, certain controlparameters need to be checked: theLimited Range Position Settings, theMotion Inhibit Time and itsDeadband. There are an additionaltwo "Action on Loss of Signal"parameters relating only to Modbusand Profibus systems that also needto be checked.Limited Range Positioning is aselectable option whereby positioninglimits, 0% and 100%, can be atdifferent positions to those used fordigital Closed and Open limitcommands. Limited range positioningcan be set using the [FL] and [FH]screens.It should be noted that the actuatorwill respond to a digital Open orClose host command by moving thevalve to the set limits irrespective ofsettings made for positioning control.

Settings for Deadband and MotionInhibit Time affect accuracy andresponse time

Bus system positioning controlset-up screens can be suppressedto provide extra security.

Use the or key to turn on thepositioning set-up screens.

Bus System Positioning ControlScreens [On]

PRESS THE KEY


Press the key to display BusSystem Positioning Control Settings.

Once [Fl] is displayed, Press the key to display [FL]

[FL] is the position to which theactuator will move if a 0%command is sent and is theposition at which the actuator willreport 0% to the host.

The default setting is for 0% to bethe Close limit.

If altered, it is possible that theposition indicated by the actuatordisplay will differ to that indicatedby the host.

Use the or key to select thedesired valve position for a 0%command.

0% DV = Valve ClosedPRESS THE KEY


Press the key to display [FH]

[FH] is the position to which theactuator will move if a 100%command is sent and is theposition at which the actuator willreport 100% to the host.

The default setting is for 100% tobe the Open limit.

If altered, it is possible that theposition indicated by the actuatordisplay will differ to that indicatedby the host.

Use the or key to select thedesired valve position for a 100%command.

100% DV = Valve OpenPRESS THE KEY


Press the key to display [Fd]

Bus System Positioning Control Settings

9.11 Display Bus System Positioning Set-up Screens

Bus System Valve Position at 0% DV

FLOF Bus System Valve Position at 100% DV

FH

54


All positioning commands aresubject to a deadband tolerance.

The deadband sets the expectedpositioning accuracy of theactuator and is dependent onvarious factors including, actuatoroutput speed, number of turns andvalve torque. If the deadband is settoo low the valve may "hunt"around the set point.

Use the or key to display therequired setting:[00] to [99] - 0% to 9.9% of valvestroke.

2.5% Deadband


Press the key to display [Ft]

MIT sets the minimum timebetween successive positioncommands being actioned. It isused in situations to reduce thenumber of starts per hour and tosmooth out fluctuations ifcontinuous positioning isimplemented.

Setting the longest possible timewhile maintaining acceptablecontrol will maximise the life of themotorised valve.

Use the or key to display therequired setting:[02] to [99] - 2 to 99 seconds.

5 Second MIT


Press the key to display [FA]

Modbus and Profibus modules canbe set to respond on loss of hostcommunication by positioning thevalve. Modbus checks for a loss ofgeneral highway communicationswhereas Profibus checks for a lossof communications addressedspecifically to itself.

The default setting is off [OF] andthe default timeout is 255 sec.

Use the or key to display therequired setting:[On] Failsafe determined bysetting [FF][OF] No failsafe action

Failsafe Action Enabled


Press the key to display [FF]

Modbus or Profibus failsafe actionwhen [FA] is enabled.

Use the or key to display therequired setting:[Lo] Close valve[SP] Stay put [HI] Open valve

Failsafe Close

PRESS THE KEY


55

Bus SystemDeadband Adjustment

Fd Bus SystemMotion Inhibit Time (MIT)

Ft Modbus & ProfibusAction on Loss of Signal

FA Modbus & ProfibusFailsafe Action

FF


56

Setting instructions for actuatorincluding an interrupter timer.

The interrupter timer enablespulsed “stop/start” operation by theactuator as a response to local andremote control commands.This effectively increases the valvestroke time and can be adjusted toprevent hydraulic shock (waterhammer) and flow surges inpipelines.

The interrupter timer is an optionalextra – check wiring diagram forinclusion.

When fitted, the timer will bemade available for operation.

The Interrupter cannot beenabled or disabled using theSetting Tool.

Interrupter Timer Interrupter TimerDisabled Enabled

When the timer option is availablean additional series of settings canbe accessed by pressing the key

NOTE: If the timer option is notavailable pressing the key will notaccess setting.

Press the key to displayinterrupter timer set-up screens.

The default for timer direction is[CL] , timer operation will start inclosing and stop in opening –pulsing operation around the closeposition.

If pulsing operation is required tostop in closing and start in opening– around the open position,use the or key.The display will change to [OP] .PRESS THE KEY.The displayed option will flashindicating that it has been set.

Pulsed Operation Around theClosed Position

NOTE: Instructions [JC] and [JO]are for timer operation around theClosed position. For timing aroundthe Open position, read stop forstart [JC] and start for stop [JO] .Press the key to display [JC] .

Using the or key select theposition for the TIMER TO STARTWHEN THE VALVE IS CLOSING .

[ ][ ] = valve closed, [01]-[99] = percentage open [ ] = valve open

Timer Set to Start Pulsing whenClosing Valve Reaches 25% Open

PRESS THE KEY


If the timing is not required in theclosing stroke select [JC] to [ ][ ]valve closed position.

Press the key to display [JO] .

OptionInterrupter Timer

9.12 Interrupter TimerEnabled/Disabled

OJ Interrupter TimerDirection

Jd Position in Valve ClosingStroke for Timer to Start

JC


Using the or key select theposition for the TIMER TO STOPWHEN THE VALVE IS OPENING .

[ ][ ] = valve closed[00]-[99] = percentage open[ ] = valve open

Timer Set to Stop Pulsingwhen Opening ValveReaches 25% Open

PRESS THE KEY.


If timing is not required in theopening stroke select [JO] to [ ][ ].

Press the key to display [Jn].

Using the or key select theactuator run period in the range 1–99 seconds.

Actuator Run PeriodSet for 5 Seconds

PRESS THE KEY.


Press the key to display [JF] .

Using the or key select theactuator stop period in the range1–99 seconds.

Actuator OFF PeriodSet for 25 Seconds

PRESS THE KEY.


Press the key to display [JE]

The interrupter timer may beoverridden when the actuator isunder ESD signal command. Thiswill mean the actuator will run tolimit without “stop/start” actionunder ESD command.

Refer to A1 - A3 (refer to page 33for ESD settings).

The default for ESD overrideinterrupter timer is [OF] . Theinterrupter timer will continue“stop/start” action during ESDaction.

If ESD must override the timer usethe or to display [On]

ESD Override Timer OFF

PRESS THE KEY


57

Position in Valve OpeningStroke for Timer to Stop

JOContactor On Time

JnContactor Off Time

JF ESD OverrideInterrupter Timer

JE


58

An actuator fitted with theinterrupter timer and set as theexample shown in theseinstructions would operate at:

Rated speed from full Open to 25%Open.

1/6 rated speed from 25% Open toFully Closed and from Fully Closedto 25% Open.

Rated speed from 25% Open toFully Open.

With a Folomatic option fitted andthe Interrupter Timer enabled, theFolomatic Motion Inhibit Timermust be adjusted to the same timeas that set for the Interrupter Timer“contactor off”.

Failure to do so will cause theactuator response to defer to thelower time which may causecontrol or process problems.

For “ON” and “OFF” times inexcess of 99 seconds apply toRotork.

The default setting for Setting ToolLocal Control is [OF] .

To enable Setting Tool Controlpress the or key to select [On].

PRESS THE KEY.


With the red control selector inLocal, the Setting Tool control keysare active (refer to page 17)

Local Setting Tool Control Enabled

Vandal resistant actuators ONLY(red/black selectors not supplied).For control, the selection of [Or] isas follows:[On] Local Setting Tool control only.[OF] Local/Remote Control disabled.[rE] Remote Control only.

The default setting for this option isenabled [On]. This ensures thatthe actuator cannot be operatedelectrically if the position sensingcircuits have not been updatedafter manual operation during acombined power failure and lowbattery condition – a blackout.

This feature may be disabled byusing the or key so that [OF]appears in the lower part of thedisplay. If the feature is disabled itis important that the actuator is notmanually operated during a powerfailure if the battery is low. Manualoperation can be prevented bylocking the actuator hand/autolever in the auto position.

PRESS THE KEY.The displayed option will flashindicating that it has been set.

Example Note Setting ToolLocal Control [O r]

9.13 Inhibit OperationAfter Power Loss [OS]

9.14


All IQ functions are configured to a set of Rotork default (standard)settings before despatch, see the table opposite. When requested,alternative settings specified with the order will be used. When sitecommissioning takes place, entered settings overwrite Rotork defaults andthese "current" settings are used for operation along with the remainingunadjusted defaults.

Should difficulty be encountered during commissioning the default settingscan be reinstated, returning the actuator configuration to its originalmanufactured state. Site commissioning must then begin again.

There are two levels of default:d1 Rotork standard or customer specified primary and secondarysettings.

d2 Limit positions only - factory set turns and limits.

NOTE: Settings associated with control options Folomatic, Pakscan,Modbus Profibus and Foundation Fieldbus are not affectedby d1 or d2. Functions will remain as set.

If d1 is entered, all Primary and Secondary Functions except limitpositions will return to their default setting. See the table oppositefor Rotork standard settings. Primary setting (except limits) andsecondary settings must then be checked and reset as required.(refer to Primary Functions page 20 and Secondary Functions page 30.)

If d2 is entered the limits will be reset to 25 output turns apart, withthe actuator positioned at 50% (12.5 output turns). Limits must thenbe reset to the suit the valve. (refer to Primary Functions page 20)

Rotork standard [d1] Default settings:

Function [d1] Default Setting[P?] Password Unaffected - will remain

as set[Ir] IrDA - Insight [On] IrDA Enabled[Ic] Cell Phone [OF] DisabledPrimary Functions[C1] Close Direction [C] Clockwise[C2] Close Action [Cl] Close Limit[C3] Open Action [Ol] Open Limit[tC] Close Torque [40] 40% of rated[tO] Open Torque [40] 40% of rated Secondary Functions[r1] Indication Contact S1 [Cl]/[ nO] Close, Normally Open[r2] Indication Contact S2 [OP]/[ nO]Open, Normally Open[r3] Indication Contact S3 [Cl]/[ nC] Close, Normally Closed[r4] Indication Contact S4 [OP]/[ nO]Open, Normally Closed[A1] ESD Action [SP] Stay put on ESD[A2] ESD Contact Type [nO] Normally Open (make

for ESD)[A3] ESD Thermostat Override [OF] Thermostats Active

during ESD[A4] ESD Override Interlocks [OF] Interlocks Active during

ESD[A5] ESD Override Local Stop [OF] Local Stop Active during

ESD[A6] Maintained Local Control [On] Maintains in Local

Control

59

Default Options[d1] and [d2]

9.15


60

Rotork standard [d1] Default settings continued:

Function [d1] Default Setting[A7] 2-wire Remote Control [OP] Open valve on 2-wire

signal[A8] Interlocks [OF] I/L function disabled[A9] Conditional Control [OF] Function disabled[OE] Option Extra Indication

Contacts [OF] Unless fitted. See wiringdiagram

[OI] Option CPT [HI] 4mA at Closed[OF] Option Folomatic [OF] Unless fitted. See wiring

diagram[Od] Remote Source [rE] Unless option fitted.

(refer to 9.7 page 41)[OP] Option Bus System Control [OF] Unless fitted. See wiring

diagram[OJ] Option Interrupter Timer [OF] Unless fitted. See wiring

diagram[Or] Setting Tool Local Control [OF] Setting Tool Control

disabled[OS] Power Loss Inhibit [On] Protection on

Option Extra Indication Contacts (when fitted) - refer to wiring diagram[r5] Indication Contact S5 [Cl]/[ nO] Close, normally open[r6] Indication Contact S6 [OP]/[ nO] Open, normally open[r7] Indication Contact S7 [tl]/[ nO] Torque Trip Mid Travel,

normally open[r8] Indication Contact S8 [rE]/[nO] Remote Selected,

normally open

The Rotork standard default settings are subject to change withoutnotice.

If specified with order, [d1] settings will be configured as requested.

To reinstate [d1] settings, With [d1 ] displayed

PRESS THE KEY

The setting bars will flash, indicating the [d1] default settings have beenreinstated.

To reinstate factory set limits (25 turns apart, actuator positioned at 50%)With [d2] displayed.

PRESS THE KEY

The setting bars will flash, indicating the [d2] default limits have beenreinstated.

[d1] Displayed [d2] Displayed

Default Options[d1] and [d2]

9.15


61

MaintenanceEvery Rotork actuator has beenfully tested before dispatch to giveyears of trouble-free operationproviding it is installed, sealed andcommissioned in accordance withthe instructions given in thispublication.The IQ actuator’s unique doublesealed, non-intrusive enclosureprovides complete protection forthe actuator components.Covers should not be removed forroutine inspection as this may bedetrimental to the future reliabilityof the actuator.The electrical control module coveris bonded by the Rotork qualitycontrol seal. It should not beremoved as the module containsno site serviceable components.All electrical power supplies to theactuator must be isolated beforeany maintenance or inspection iscarried out, except replacement ofthe battery.Electrical supplies must be isolatedbefore actuator covers other thanthe battery sealing plug areremoved.

Routine maintenance shouldinclude the following:* Check actuator to valve fixing

bolts for tightness.* Ensure valve stems and drive

nuts are clean and properly lubricated.

* If the motorised valve is rarely operated, a routine operating schedule should be set up.

* Replace actuator battery every 5 years.

The Actuator BatteryThe battery supports the actuatorposition updating circuits and theposition (LCD) display when themain power supply is turned off.It ensures the current position isupdated and displayed whenmanual operation takes place withthe main power turned off.The battery is not required toretain any actuator settings.WARNING:The battery holder in theactuator gearcase also protectsthe user from the hazardous liveconnections inside the actuatorand therefore it must not bedamaged. The actuator must be

isolated or disconnected if thebattery holder has to beremoved from the actuatorgearcase.A unique circuit has beenincorporated into the batteryfunction of the IQ, effectivelyreducing the overall drain andsignificantly increasing the batterylife.Tests show for a typical actuator, abattery life of 7 years can beexpected.Allowing for a conservativemargin, Rotork recommend thatthe battery should be replacedevery 5 years.Battery level status is indicated byan icon on the actuator display,refer to 3.4 Alarm Indication.(refer to page 5)If the battery icon is displayed thebattery must be replaced.

Battery ReplacementIf the actuator is located within ahazardous area permission mustbe obtained in the form of a "hotwork permit" or other localregulation before removal and/orreplacement of the battery.Removal of the battery with themain electrical power switched offwill result in stored Dataloggerrecords being lost. It is thereforerecommended that the battery isreplaced with the main electricalsupply to the actuator switched on.If main electrical power is notavailable or if main power has beenswitched off while the battery wasdischarged, it is recommended thatthe actuator limits be checked afterbattery replacement.(refer to section 8 CommissioningPrimary Functions, page 20).Battery RemovalThe actuator must be selected toStop using the red selector. (refer topage 3) Access to the battery is via alabelled sealing plug situated on thetop of the main gearcase next tothe handwheel hub.

Maintenance, Monitoring& Troubleshooting

10


62

Use an 8mm allen key to removethe sealing plug, ensuring the "O"ring seal remains on the plug.Disconnect the battery wiring loomfrom the battery terminals. Usingthe black pull strap, lift the batteryout of the rubber sealing pocket.

Fig. 33Battery TypesFor European hazardous areacertified actuators (CENELEC) usean Ultralife U9VL lithiummanganese dioxide battery only.For FM and CSA certifiedenclosures use an Ultralife U9VLlithium manganese dioxide battery.Equivalent, UL recognised,batteries may be used.For watertight (WT) actuatorenclosures use an Ultralife U9VLlithium manganese dioxide batteryor any equivalent 9V battery.

If in doubt regarding the correctbattery type, contact Rotork.

Fitting Replacement BatteryFit the pull strap around thereplacement battery and insert intothe rubber sealing pocket.Reconnect the battery wiring loomto the battery terminals. Refit thebattery sealing plug ensuring "O"ring is in good condition andcorrectly fitted. Hand tightensealing plug using an 8mm allenkey.

OilUnless specially ordered forextreme climatic conditions, Rotorkactuators are dispatched withgearcases filled with SAE 80EP oilwhich is suitable for ambienttemperatures ranging from-22°F/-30°C to 160°F/70°C.

IQ actuators do not require regularoil changes.

(refer to Weights and Measures section 11, page 70)

Torque and Position MonitoringThe IQ range of actuatorsincorporate real time, instantaneousTorque + Position monitoring asstandard.Torque + Position can be used tomonitor valve performance duringoperation. The effect of processchanges (differential pressure etc.)can be evaluated. Tight spots invalve travel can be pinpointed aswell as gauging torque developedthrough stroke for torque valuesetting. (refer to pages 25, 26.)

Using the Setting Tool, the displaycan be set to indicate Torque andPosition as follows:

With the actuator displayingCurrent Position and selected toLocal or Stop, using the SettingTool,

PRESS THE KEY.

The display will split, the topindicating the instantaneous torque(as a % of rated), the bottomindicating the measured position(% open).

Example shows 19% (of rated)torque at 50% open position.Display torque range: [00] to [99]%of rated torque in 1% increments.For values of torque above 99% thedisplay will indicate [HI] .Display position range:[ ][ ] = Valve Closed[00]-[99] = Percent Open[ ] = Valve OpenFor a stationary actuator thedisplay will indicate the actualtorque value as applied by theactuator.

To keep the torque + positiondisplay active press the orkeys. The display will remain activefor approximately 5 minutes fromthe last key operation.

Maintenance, Monitoring& Troubleshooting cont.

10


63

TroubleshootingThe IQ range of actuators is theworld’s first that can becommissioned and interrogatedwithout removing electrical covers.Help Screen diagnostics enablefast and complete fault finding tobe carried out.

With power off, the actuatordisplay is not backlit. Positionindicator lamp not illuminated.With mains power on, theactuator’s display should be backlit.(refer to section 3.3 page 4 – TheActuator Display)

Check that 3 phase supply isavailable and is of the correctvoltage as stated on the actuatornameplate. Measure voltage phaseto phase across terminals 1, 2 and3 of the actuator terminal bung.

With power Off, the actuatordoes not display position.With mains power off the actuatorbattery supports position indicationliquid crystal display only.

(refer to section 3.3 page 4 – TheActuator Display)

If the display is blank the actuatorbattery must be replaced and thelimits of travel reset.(refer to section 10, page 61 – TheActuator Battery)

With the actuator powered up andLocal or Stop selected, eight HelpScreens can be accessed usingthe Setting Tool.(refer Fig 30 page 29 for theirlocation).

With Remote selected press the key on the Setting Tool twice.

The Help Screens will displayed.

Each screen uses bars to indicatethe status of a particular control orindication function. Each barreacts to changes in the status ofits actuator function by turning "on"or "off ".

For troubleshooting, access thefollowing Help Screens and refer totext:H1 - Factors inhibiting electrical

operation.H2 - Monitor battery level and ESD

control input.H3 - Monitor the position limit

and actuator power supplystatus.

H4 - Monitor remote control inputs to the actuator.

H5 - Monitor remote interlocks local control inputs and motor thermostats.

H6 - Monitor torque switch status and IR Setting Tool communication for vandalproof applications.

H7 - Monitor travel limits, centre column and position limit status. status.

H8 - Monitor the actuators position sensing devices.

H9 - Rotork use only.Help screen bars shown are undefined and may be ON,OFF or flashing.

Maintenance, Monitoring& Troubleshooting cont.

10Help Screens

10.1


Help Screen 1

POSITION ERRORBar ON = Current Position ErrorPresent.

During power up the actuatorposition processor compares thecurrent position to that stored inthe Eeprom. If there is adiscrepancy this is shown as acurrent position error.

Re-setting of both actuator limitsshould now be carried out.(refer to page 27)

BATTERY LOW ON POWER UPBar ON = Low battery detectedOn Power Up .

If [OS] is selected [On] (set asdefault ) the actuator operation willbe inhibited when powered up witha discharged battery.(refer to [OS] page 58).

The battery should be replaced atthe earliest opportunity.(refer to page 61).

LOCAL CONTROLS ERRORBar ON = Invalid Local ControlSignals Detected.

For example if a Local Open andClose signal is detected at thesame time this would be classedas an invalid or fault condition.

PHASE LOSSBar ON = Phase Lost (3 PhaseActuators Only)

Loss of third monitored powersupply phase connected toactuator terminal 3.

Help Screen 2

BATTERY DISCHARGEDBar ON = Battery Discharged

Bar ON when the battery is nolonger able to support actuatorfunctions under loss of powerconditions.

The battery must be replaced(refer to section 10 page 61) andlimit positions reset.(refer to [LC] and [LO] page 27).

LOW BATTERYBar ON = Battery level low.Bar OFF = Battery OK.

Bar ON when the battery is low butstill able to support the necessaryactuator functions.

The battery should be replaced atthe earliest possible opportunity.

ESD SIGNAL ACTIVEBar ON = ESD Signal is present.

When applied, an EmergencyShutdown Signal will override anyexisting local or remote controlsignal, causing the actuator torespond in the direction selectedfor ESD.

The ESD function will bedetermined by the settings onControl Mode Configurationscreens [A1] to [A5] .(refer to section 9.3 page 33)

The actuator will not respond toany local or remote control whilean ESD signal is maintained.

64

Factors InhibitingElectrical Operation

H1

PositionError

PhaseLoss

LocalControls

Error

Battery Lowon

Power-up

H1

Battery Level andESD Control Input

H2

ESDActive

LowBattery

BatteryDischarged

H2


65

Help Screen 3

CLOCKWISE LIMITBar ON = Actuator has reachedclockwise limit of travel .

ANTI-CLOCKWISE LIMITBar ON = Actuator has reachedAnti-clockwise limit.

PHASE LOSSBar ON = Phase Lost (3 PhaseActuators Only )

Loss of third, monitored powersupply phase connected toactuator terminal 3.

Help Screen 4

All remote signals designated with‘1’ are standard hard wired remoteinputs.

When a Pakscan, Profibus orFoundation Fieldbus card is fitted,remote control inputs aredesignated with a ‘2’.

REMOTE OPEN 1Bar OFF = Remote Open SignalPresent.

REMOTE CLOSE 1Bar OFF = Remote Close SignalPresent.ESD 1Bar OFF = ESD signal present.

REMOTE MAINTAIN 1Bar OFF = Remote Maintainsignal present.Bar ON = Remote Maintain notpresent and/or Remote Stopactive.

REMOTE OPEN 2Bar OFF = Remote Open signalpresent from BUS option pcb.

REMOTE CLOSE 2Bar OFF = Remote Close signalpresent from BUS option pcb.

ESD 2Bar OFF = ESD signal presentfrom BUS option pcb.

REMOTE MAINTAIN 2Bar OFF = Remote Maintainsignal present from BUS optionpcb.

Help Screen 5

OPEN INTERLOCKBar ON = Open Interlock Active.

Unauthorised Open electricaloperation can be prevented byinterlocking the actuator (Open)control with an external interlockcontact.

If external interlocks are notrequired the interlock function mustbe selected OFF.

Position Limit & Power Supply Status

H3

ClockwiseLimit

PhaseLoss

AntiClockwiseLimitH3

Remote ControlInputs

H4

RemoteOpen 1

RemoteMaintain 2

ESD 2

RemoteClose 2

RemoteOpen 2

RemoteMaintain 1

ESD 1

RemoteClose 1

H4

Remote Interlocks, Local Control Inputs, & T/stat

H5

OpenInterlock

Local Stopnot

Selected

ThermostatTripped

Local Opennot Present

Local Closenot

Present

Remotenot

Selected

Local notSelected

CloseInterlock

H5


66

CLOSE INTERLOCKBar ON = Close Interlock Active.

Unauthorised Close electricaloperation can be prevented byinterlocking the actuator (Close)control with an external interlockcontact.

If external interlocks are notrequired the interlock function mustbe selected OFF.

REMOTE NOT SELECTEDBar ON = Remote control notselected.Bar OFF = Remote controlselected.

LOCAL CLOSE NOT PRESENTBar ON = Local Close signal notpresent.Bar OFF = Local Close signalpresent.

LOCAL OPEN NOT PRESENTBar ON = Local Open signal notpresent.Bar OFF = Local Open signalpresent.

THERMOSTAT TRIPPEDBar ON = Thermostat tripped.

The actuator motor is protected bythermostats.

Should the motor becomeoverheated the thermostats will tripand the actuator will stop. Oncooling the thermostat willautomatically reset, enablingoperation. See the actuatornameplate for the motor rating.

LOCAL STOP NOT SELECTEDBar ON = Local Stop notselected.Bar OFF = Local stop selected.

LOCAL NOT SELECTEDBar ON = Local control notselected.Bar OFF = Local controlselected.

Help Screen 6

When actuators are supplied forVandal Proof applications the localcontrol knobs are removed toprevent unauthorised operation.

The local control functions are thencarried out by using the Infra-redSetting Tool.

LOCAL CONTROLS NOT FITTEDBar OFF = Local controls fitted(standard).Bar ON = Local controls notfitted (vandal proof).

TORQUE SWITCH TRIPPEDBar OFF = Torque switchtripped.When the actuator generates avalue of torque equal to that set forOpen (when opening) or Close(when closing ) it will stop,protecting itself and the valve fromdamage. This feature is known asOver Torque Protection.

Once a torque trip has occurredfurther operation IN THE SAMEDIRECTION is prevented.

This 'latching' of the event protectsthe actuator and valve fromrepeated “hammering” against theobstruction as a response to amaintained control signal.

To "delatch" the actuator it must bereversed.

(for actuator torque adjustment,refer to [tC ] and [tO] pages 25and 26).

Torque Switch Status& IR Setting Tool Commsfor Vandal Proof Applications

H6

IR RemoteControl notSelected

IR LocalControl

Disabled

IR ClosedSignal not

Present

IR OpenSignal notPresent

TorqueSwitchTripped

LocalControlsnot FittedH6

Remote Interlocks, Local Control Inputs, & T/stat cont.

H5


IR OPEN SIGNAL NOT PRESENTBar OFF = IR Open signalpresent.

IR CLOSE SIGNAL NOTPRESENTBar OFF = IR Close signalpresent.

IR LOCAL CONTROL DISABLEDBar OFF = IR Local controlenabled

To operate the actuator locally withthe IR Setting Tool (refer to theoption selection screen [Or]section 9.13 page 58)

[Or] must be selected to [On].

IR REMOTE CONTROL NOTSELECTED.Bar OFF = IR Remote controlselected. (Vandal proof units only )

When actuator is supplied withoutlocal controls for vandal proofapplications the option selectionscreen [Or] must be set to [rE] forRemote operation.(refer to section 9.13 page 58).

Help Screen 7

OPEN LIMITBar ON = Actuator has reachedopen limit .

CLOSE LIMITBar ON = Actuator has reachedClose limit.

ACTUATOR MOVINGBar ON = Actuator moving

SWITCH CONTACTS S1, S2, S3, S4Bar ON = S contact is closecircuit .

Bar indication is real time andreactive.(refer to section 9.2 [r1] page 31for configuration of "S" contacts).

Help Screen 8

POSITION SENSOR ASenses output rotation. Used forthe position sensing circuit.Correct operation of the sensor isindicated by the bar being ON (andOFF) 12 times per outputrevolution. When the motor isrunning, ON and OFF bit durationshould be equal.

POSITION SENSOR BSenses output rotation. Used forthe position sensing circuit.Correct operation of the sensor isindicated by the bar being ON (andOFF) 12 times per outputrevolution.

When the motor is running, ONand OFF bit duration should beequal.

For the two sensors; A and B,correct operation is indicated bythe following truth table.

To observe this function, selectmanual operation and turn theactuator handwheel clockwise,starting with all sensors OFF:

CLOCKWISE 30 Deg.

Sensor B 0 1 1 0 0

Sensor A 0 0 1 1 0

67

Torque Switch Status &IR Setting Tool Comms for Vandal Proof Applications cont.

H6 Travel Limits,Centre Column &Remote Indication Outputs

H7

OpenLimit Relay 4

Relay 3

Relay 2

Relay 1

ActuatorMoving

CloseLimit

H7

Actuator PositionSensing Devices

H8

PositionSensor A

PositionSensor B

H8


68

IQ Insight software tool for PC hasbeen developed to enable theactuator configuration and on-board datalogger to bereconfigured and analysed.

To enable communication with IQInsight the actuator IrDA interfacemust be enabled.

A PC running IQ Insight softwaremay be located at the actuator or,using a cell phone link, at a remotesite.

(for information on IQ Insightsoftware refer to publicationE111E)

The default setting for IQ IrDA is[On], enabling IrDA.

To disable IrDA use the or key.The display will change to [OF]

PRESS THE KEY

The displayed option will flashindicating it has been set.

IQ Insight - IrDA CommunicationEnabled.

Using IQ Insight software tool,remote diagnostics can be enabledusing a cell phone located at theactuator to transmit and receivedata to and from a remote PCrunning IQ Insight software.

The cell phone must be IrDAcompatible and have access to atransmit/receive data line (contactyour cell phone manufacturer andservice provider).

(for information on IQ Insightsoftware refer to publicationE111E)

The actuator IrDA feature must beenabled - refer to [Ir] IQ Insight -IrDA Comms.

Before starting, the cell phonemust be configured for "data" asopposed to "voice" and bepositioned in direct line of sight tothe actuator display, no more than0.5m (2ft) from the display.

The default setting for IQ Insight -Cell Phone is [OF]

To enable remote diagnostics usethe or key. The display willchange to [On]

PRESS THE KEY

The actuator display willautomatically return to indicatingthe current position.

The actuator will search for acompatible IrDA device within rangefor approximately 30 seconds.

On establishing communication,the actuator display will indicatethe symbol shown below

IrDA Diagnostics &Config. - IQ InsightIrDA Comms - [Ir]

10.2 IrDA Diagnostics &Config. - IQ InsightCell Phone - [Ic]

10.2


69

The cell phone must be kept withinrange for the duration of the remotediagnostic session.

If communication is not establishedor is lost, after 30 seconds theactuator will stop searching.

To resume remote cell phonediagnostics the process outlinedabove must be started again.

IQ Insight software is available freeof charge from the Rotork web site,www.rotork.com, or for sale as a"pak" which includes an IrDA seriallink for convenient connection whenusing a notebook PC in the field.

NOTE: The use of a notebook PCor cell phone with actuators locatedin hazardous areas will be subjectto local regulations.

It is the responsibility of the user toseek guidance and permission.

The IQ Setting Tool is certifiedIntrinsically Safe (IS) and thereforecan be used in defined hazardousareas. (refer to page 17)

The Rotork IS Communicator Toolis available for local configuration,analysis and transportation ofactuator data to safe areas.Contact Rotork for advice.

IrDA Diagnostics &Config. - IQ InsightCell Phone - [Ic] cont .

10.2


70

OilUnless specially ordered forextreme climatic conditions, Rotorkactuators are dispatched withgearcases filled with SAE 80EP oilsuitable for ambient temperaturesranging from -22°F/-30°C to160°F/70°C.

NOTE: Excludes second stagegearbox if fitted.

Food grade lubricating oil isavailable as an alternative: contactRotork.

Weights and Measures11

Actuator Size Nett Weight Oil Capacitykg/lbs litres/pt.-US

IQ10 32/70 0.3/0.63

IQ12 32/70 0.3/0.63

IQ18 32/70 0.3/0.63

IQ20 52/115 0.8/1.7

IQ25 52/115 7.8/1.7

IQ35 75/165 1.1/2.3

IQ40 200/441 7.5/15.8

IQ70 215/474 7.0/14.7

IQ90 230/507 7.0/14.7

IQ91 220/485 7.0/14.7

IQ95 230/507 7.0/14.7

If your Rotork actuator has been correctly installed and sealed, it will give yearsof trouble-free service.

Should you require technical assistance or spares, Rotork guarantees the best service in the world. Contact your local Rotork representative or the factory direct at the address on the nameplate, quoting the actuator type and serial number.


71

0000 0000 00 0

0000 0001 01 1

0000 0010 02 2

0000 0011 03 3

0000 0100 04 4

0000 0101 05 5

0000 0110 06 6

0000 0111 07 7

0000 1000 08 8

0000 1001 09 9

0000 1010 0A 10

0000 1011 0B 11

0000 1100 0C 12

0000 1101 0D 13

0000 1110 0E 14

0000 1111 0F 15

0001 0000 10 16

0001 0001 11 17

0001 0010 12 18

0001 0011 13 19

0001 0100 14 20

0001 0101 15 21

0001 0110 16 22

0001 0111 17 23

0001 1000 18 24

0001 1001 19 25

0001 1010 1A 26

0001 1011 1B 27

0001 1100 1C 28

0001 1101 1D 29

0001 1110 1E 30

0001 1111 1F 31

0010 0000 20 32

0010 0001 21 33

0010 0010 22 34

0010 0011 23 35

0010 0100 24 36

0010 0101 25 37

0010 0110 26 38

0010 0111 27 39

0010 1000 28 40

0010 1001 29 41

0010 1010 2A 42

0010 1011 2B 43

0010 1100 2C 44

0010 1101 2D 45

0010 1110 2E 46

0010 1111 2F 47

0011 0000 30 48

0011 0001 31 49

0011 0010 32 50

0011 0011 33 51

0011 0100 34 52

0011 0101 35 53

0011 0110 36 54

0011 0111 37 55

0011 1000 38 56

0011 1001 39 57

0011 1010 3A 58

0011 1011 3B 59

0011 1100 3C 60

0011 1101 3D 61

0011 1110 3E 62

0011 1111 3F 63

0100 0000 40 64

0100 0001 41 65

0100 0010 42 66

0100 0011 43 67

0100 0100 44 68

0100 0101 45 69

0100 0110 46 70

0100 0111 47 71

0100 1000 48 72

0100 1001 49 73

0100 1010 4A 74

0100 1011 4B 75

0100 1100 4C 76

0100 1101 4D 77

0100 1110 4E 78

0100 1111 4F 79

0101 0000 50 80

0101 0001 51 81

0101 0010 52 82

0101 0011 53 83

0101 0100 54 84

0101 0101 55 85

0101 0110 56 86

0101 0111 57 87

0101 1000 58 88

0101 1001 59 89

0101 1010 5A 90

0101 1011 5B 91

0101 1100 5C 92

0101 1101 5D 93

0101 1110 5E 94

0101 1111 5F 95

0110 0000 60 96

0110 0001 61 97

0110 0010 62 98

0110 0011 63 99

0110 0100 64 100

0110 0101 65 101

0110 0110 66 102

0110 0111 67 103

0110 1000 68 104

0110 1001 69 105

0110 1010 6A 106

0110 1011 6B 107

0110 1100 6C 108

0110 1101 6D 109

0110 1110 6E 110

0110 1111 6F 111

0111 0000 70 112

0111 0001 71 113

0111 0010 72 114

0111 0011 73 115

0111 0100 74 116

0111 0101 75 117

0111 0110 76 118

0111 0111 77 119

0111 1000 78 120

0111 1001 79 121

0111 1010 7A 122

0111 1011 7B 123

0111 1100 7C 124

0111 1101 7D 125

0111 1110 7E 126

0111 1111 7F 127

1000 0000 80 128

1000 0001 81 129

1000 0010 82 130

1000 0011 83 131

1000 0100 84 132

1000 0101 85 133

1000 0110 86 134

1000 0111 87 135

1000 1000 88 136

1000 1001 89 137

1000 1010 8A 138

1000 1011 8B 139

1000 1100 8C 140

1000 1101 8D 141

1000 1110 8E 142

1000 1111 8F 143

1001 0000 90 144

1001 0001 91 145

1001 0010 92 146

1001 0011 93 147

1001 0100 94 148

1001 0101 95 149

1001 0110 96 150

1001 0111 97 151

1001 1000 98 152

1001 1001 99 153

1001 1010 9A 154

1001 1011 9B 155

1001 1100 9C 156

1001 1101 9D 157

1001 1110 9E 158

1001 1111 9F 159

1010 0000 A0 160

1010 0001 A1 161

1010 0010 A2 162

1010 0011 A3 163

1010 0100 A4 164

1010 0101 A5 165

1010 0110 A6 166

1010 0111 A7 167

1010 1000 A8 168

1010 1001 A9 169

1010 1010 AA 170

1010 1011 AB 171

1010 1100 AC 172

1010 1101 AD 173

1010 1110 AE 174

1010 1111 AF 175

1011 0000 B0 176

1011 0001 B1 177

1011 0010 B2 178

1011 0011 B3 179

1011 0100 B4 180

1011 0101 B5 181

1011 0110 B6 182

1011 0111 B7 183

1011 1000 B8 184

1011 1001 B9 185

1011 1010 BA 186

1011 1011 BB 187

1011 1100 BC 188

1011 1101 BD 189

1011 1110 BE 190

1011 1111 BF 191

1100 0000 C0 192

1100 0001 C1 193

1100 0010 C2 194

1100 0011 C3 195

1100 0100 C4 196

1100 0101 C5 197

1100 0110 C6 198

1100 0111 C7 199

1100 1000 C8 200

1100 1001 C9 201

1100 1010 CA 202

1100 1011 CB 203

1100 1100 CC 204

1100 1101 CD 205

1100 1110 CE 206

1100 1111 CF 207

1101 0000 D0 208

1101 0001 D1 209

1101 0010 D2 210

1101 0011 D3 211

1101 0100 D4 212

1101 0101 D5 213

1101 0110 D6 214

1101 0111 D7 215

1101 1000 D8 216

1101 1001 D9 217

1101 1010 DA 218

1101 1011 DB 219

1101 1100 DC 220

1101 1101 DD 221

1101 1110 DE 222

1101 1111 DF 223

1110 0000 E0 224

1110 0001 E1 225

1110 0010 E2 226

1110 0011 E3 227

1110 0100 E4 228

1110 0101 E5 229

1110 0110 E6 230

1110 0111 E7 231

1110 1000 E8 232

1110 1001 E9 233

1110 1010 EA 234

1110 1011 EB 235

1110 1100 EC 236

1110 1101 ED 237

1110 1110 EE 238

1110 1111 EF 239

1111 0000 F0 240

1111 0001 F1 241

1111 0010 F2 242

1111 0011 F3 243

1111 0100 F4 244

1111 0101 F5 245

1111 0110 F6 246

1111 0111 F7 247

1111 1000 F8 248

1111 1001 F9 249

1111 1010 FA 250

1111 1011 FB 251

1111 1100 FC 252

1111 1101 FD 253

1111 1110 FE 254

1111 1111 FF 255

Binary - HexadecimalDecimal Conversion Table

BHD

BINARY HEX DEC BINARY HEX DEC BINARY HEX DEC BINARY HEX DEC BINARY HEX DEC BINARY HEX DEC BINARY HEX DEC BINARY HEX DEC


If your Rotork actuator has beencorrectly installed and sealed, it willgive years of trouble-free service.

Should you require technicalassistance or spares, Rotorkguarantees the best service in theworld. Contact your local Rotorkrepresentative or the factory directat the address on the nameplate,quoting the actuator type and serialnumber.

AlgeriaTel: + 213 6 37 4854Fax: + 213 6 37 2613E-Mail:

ArgentinaTel: +54 11 4755 5560/4753 7533Fax: +54 11 4755 5560/4753 7533E-Mail: [email protected]

AustraliaRotork Company HQTel: +61 3 53 381566Fax: +61 3 53 381570E-Mail: [email protected]

BrisbaneRotork Company Tel: +61 7 3373 2050Fax: +61 7 3255 5388E-Mail:

SydneyRotork Company Tel: +61 2 9 567 2735Fax: +61 2 9 567 2739E-Mail:

Western Australia Agent Tel: +61 8 9314 1827Fax: +61 8 9314 1837E-Mail: [email protected]

AustriaAgentTel: +43 7224 66008Fax: +43 7224 66008E-Mail: [email protected]

BahrainRotork Regional Office Tel: +973 791 976Fax: +973 791 976E-Mail: [email protected]

BahrainAgentTel: +973 727790Fax: +973 727811E-Mail: [email protected]

BelgiumAgentTel: +32 2 7263300Fax: +32 2 7263633E-Mail: [email protected]

BoliviaAgentTel: +591 3 532615Fax: +591 3 552528E-Mail: [email protected]

BrazilAgentTel: +55 71 235 6588Fax: +55 71 235 3299E-Mail: [email protected]

BruneiAgentTel: +673 3 336122Fax: +673 3 336142E-Mail: [email protected]

CanadaRotork Company HQTel: +1 403 569 9455Fax: +1 403 569 9414E-Mail: [email protected]

CanadaEdmontonRotork Company Tel: +1 780 449 6663Fax: +1 780 449 6578E-Mail: [email protected]

CanadaMontrealRotork CompanyTel: +1 514 355 3003Fax: +1 514 355 0024E-Mail: [email protected]

CanadaS.W. OntarioRotork Company Tel: +1 519 337 9190Fax: +1 519 337 0017E-Mail: [email protected]

CanadaTorontoRotork CompanyTel: +1 905 602 5665Fax: +1 905 602 5669E-Mail: [email protected]

Caribbean (Puerto Rico)Agent Tel: +1 787 273 6450Fax: +1 787 273 6451E-Mail:

ChileAgentTel: +56 2 441 1033/699 2001Fax: +56 2 441 1023E-Mail: [email protected]

ChinaNorth/BeijingRotork Company Tel: +86 10 6497 4142/94590Fax: +86 10 6499 4591E-Mail: [email protected]

ChinaShanghaiRotork Company Tel: +86 21 6478 5015Fax: +86 21 6478 5035E-Mail: [email protected]

ChinaSichuanRotork Branch Tel: +86 28 6521191Fax: +86 28 6521056E-Mail: [email protected]

China (South)GuangzhouRotork BranchTel: +86 20 81320500Fax: +86 20 81320499E-Mail:[email protected]

ChinaHong Kong Rotork Company Tel: +852 2520 2390Fax: +852 2528 9746E-Mail:[email protected]

ColombiaAgent Main OfficeTel: +57 4 288 62 62Fax: +57 4 305 00 00E-Mail:[email protected]

Costa RicaAgent Tel: +506 228 8630/1Fax: +506 289 4350E-Mail:[email protected]

CroatiaAgent Tel: +385 1 4 577 217Fax: +385 1 4 577 22E-Mail:

CyprusAgent Tel: +357 2 434131/2,433719Fax: +357 2 433416E-Mail: [email protected]


Czech RepublicAgent Tel: +420 5 48321534Fax: +420 5 48216240E-Mail:

DenmarkAgent Tel: +45 32531777Fax: +45 32530504E-Mail:

EcuadorAgent Tel: +593 2 222 585Fax: +593 2 569 950E-Mail: [email protected]

EgyptAgent Tel: +20 2 2574830/2573456Fax: +20 2 2575695E-Mail: [email protected]

FinlandAgent Tel: +358 9 350 7410Fax: +358 9 3743590E-Mail:

FranceRotork Company Tel: +33 1 43 11 15 50Fax: +33 1 48 35 42 54E-Mail: (name)@rotork.fr

GermanyRotork CompanyTel: +49 2103 95876Fax: +49 2103 54090E-Mail: [email protected]

GreeceAgentTel: +30 1 6549433/6536610Fax: +30 1 6517810E-Mail: [email protected]

HungaryAgent Tel: +36 76 495932Fax: +36 76 495936E-Mail: [email protected]

IndiaBangaloreRotork Factory Tel: +91 80 8395576Fax: +91 80 8391601E-Mail: [email protected]

IndiaCalcuttaRotork Branch Tel: +91 33 282 3306Fax: +91 33 282 3473E-Mail: [email protected]

IndiaChennaiRotork Company Tel: +91 44 625 4219/6258136Fax: +91 44 6257108E-Mail: [email protected]

IndiaMumbaiRotork Branch Tel +91 22 5584578Fax: +91 22 5584540E-Mail: [email protected]

IndiaNew DelhiRotork BranchTel +91 11 5616305Fax: +91 11 5502840E-Mail: [email protected]

IndonesiaRotork CompanyTel +62 21 5806764Fax: +62 21 5812757E-Mail: [email protected]

Ireland (Northern)Agent Tel: +44 28 90 779222Fax: +44 28 90 773727E-Mail:

Ireland (Southern)Agent Tel: +353 1 2952182Fax: +353 1 2953713E-Mail:

CorkAgent Tel: +353 21 314 544Fax: +353 21 314 606E-Mail:

ItalyRotork Company Tel: +39 02 45703300Fax: +39 02 45703301E-Mail: [email protected]

JapanOsakaRotork Company Tel: +81 728 35 7555Fax: +81 728 35 7548E-Mail:

JapanTokyo Rotork Company HQ Tel: +81 3 3294 8551Fax: +81 3 3294 6460E-Mail: [email protected]

JordanAgentTel: +962 6 581 9982Fax: +962 6 582 5818E-Mail: [email protected]

Korea (South)Rotork Company Tel: +82 331 265 0962Fax: +82 331 265 1369E-Mail: [email protected]

KuwaitAgentTel: +965 241 5921Fax: +965 2412485E-Mail: [email protected]

LatviaAgent Tel: +371 7 315086/315087Fax: +371 7 315084E-Mail: [email protected]

LibyaAgent Tel: +218 21 47 72628/78598Fax: +218 21 47 72782E-Mail: [email protected]

LithuaniaAgent Tel: +370 7 202410Fax: +370 7 207414E-Mail: [email protected]

MalaysiaEast MalaysiaAgent Tel: +60 85 410079Fax: +60 85 419484E-Mail:

MalaysiaWest MalaysiaRotork Company Tel: +60 3 5193093Fax: +60 3 5193098E-Mail: [email protected]

MexicoAgentTel: +52 5 559 2959/2777Fax: +52 5 575 1092E-Mail: [email protected]

NetherlandsRotork Company Tel: +31 10 4146911Fax: +31 10 4144750E-Mail: [email protected]

New ZealandAuckland Agent North IslandTel: +64 9 634 0456Fax: +64 9 625 2678E-Mail:

New ZealandChristchurch Agent South Island - Head OfficeTel: +64 3 353 4665Fax: +64 3 353 4666E-Mail:


New ZealandWellington Agent North IslandTel: +64 4 477 5070Fax: +64 4 477 5049E-Mail:

NigeriaAgent Tel: +234 1 4522955/523225Fax: +234 1 4522887E-Mail: [email protected]

NorwayStavangerAgent HQTel: +47 51 835600Fax: +47 51 835650E-Mail:

NorwayBergenAgent Sales Office/WorkshopTel: +47 56 312900Fax: +47 56 312910E-Mail:

NorwayOsloAgent Sales OfficeTel: +47 67 906120Fax: +47 67 906472E-Mail:

OmanAgent Tel: +968 601438Fax: +968 699446E-Mail:[email protected]

PakistanAgent Tel: +92 21 5861509/5861510Fax: +92 21 5874674E-Mail: [email protected]

PeruAgent Tel: +51 1 330 7728Fax: +51 1 330 7728E-Mail:[email protected]

PhilippinesManila Agent Tel: +63 2 7312610/7326125Fax: +63 2 7312610E-Mail: [email protected]

PolandAgent Tel: +48 22 723 1770Fax: +48 22 723 1780E-Mail:

PortugalAgent Tel: +351 21 486 43 25Fax: +351 21 483 57 17E-Mail:[email protected]

QatarAgent Tel: +974 44 19603Fax: +974 44 19604E-Mail:[email protected]

RomaniaAgent Tel: +40 44 114187/114664Fax: +40 44 114664 ManualE-Mail: [email protected]

RussiaRotork Company Tel: +7 095 229 24 63Fax: +7 503 2349125E-Mail: [email protected]

Saudi ArabiaAgent/J.V.Tel: +966 3 833 1661Fax: +966 3 833 9369E-Mail:

Saudi ArabiaRotork Company Tel: +966 3 833 1661Fax: +966 3 834 8621E-Mail:

SingaporeRotork Company Tel: +65 4571233Fax: +65 4576011email:

South AfricaRotork Company Tel: +27 11 453 9741-3Fax: +27 11 453 9894E-Mail:

SpainRotork CompanyTel: +34 94 676 60 11Fax: +34 94 676 60 18E-Mail: [email protected]

SwedenPartilleAgent Head OfficeTel: +46 53 3763952Fax: +46 53 3763955E-Mail:[email protected]

SwedenSaffleAgent Local OfficeTel: +46 533 763952Fax: +46 533 763955E-Mail:[email protected]

SyriaAgentTel: +963 31 230 289Fax: +963 31 237 867E-Mail:

TaiwanAgentTel: +886 2 2577-1717Fax: +886 2 2577-5588E-Mail: [email protected]

ThailandRotork Company Tel: +66 2 272 7165-6Fax: +66 2 272 7167E-Mail:[email protected]

TrinidadAgent Tel: +1 868 6524889/6523422Fax: +1 868 6522651E-Mail: [email protected]

TurkeyAgent Tel: +90 216 327 34 71Fax: +90 216 327 34 72E-Mail:[email protected]

U.K.Head Office,Tel: +44 1225 733200, Fax +44 1225 333467E-mail: [email protected]

United Arab EmiratesAgent Tel: +971 2 632 5111Fax: +971 2 621 1934E-Mail: [email protected]

United States of AmericaRotork Company HQRochesterTel: +1 716 328 1550Fax: +1 716 328 5848E-Mail:[email protected]

United States of AmericaRotork Company DuluthTel: +1 770 623 6301Fax: +1 770 623 6124E-Mail:[email protected]

United States of AmericaChicago & Mid West Rotork CompanyTel: +1 815 436 1710Fax: +1 815 436 1789E-Mail:[email protected]

United States of AmericaHouston Rotork Company Tel: +1 713 7825888Fax: +1 713 7828524E-Mail:[email protected]

United States of AmericaNew York City Rotork CompanyTel: +1 716 352 3380Fax: +1 716 352 3971E-Mail:[email protected]

United States of AmericaNorth East Rotork CompanyTel: +1 814 835 8349Fax: +1 814 835 8909E-Mail: [email protected]


United States of AmericaNorthern CaliforniaRotork CompanyTel: +1 707 769 4880Fax: +1 707 769 4888E-Mail: [email protected]

United States of AmericaNorthwest AreaRotork Company Tel: +1 253 838 5500Fax: +1 253 838 5400E-Mail: [email protected]

United States of AmericaPhiladelphiaRotork Company Tel: +1 609 223 1926Fax: +1 609 223 9012E-Mail: [email protected]

United States of AmericaSouth Central RegionRotork CompanyTel: +972 745 2041Fax: +972 745 2041E-Mail: [email protected]

United States of AmericaSouthern CaliforniaRotork Company Tel: +1 949 348 2913Fax: +1 707 769 4888E-Mail: [email protected]

Venezuela & N. AntillesRotork Company HQTel: +58 2 285 5232/4208/4336Fax: +58 2 285 8050/286 7785E-Mail: [email protected]

Venezuela & N. AntillesCagua Rotork Company Tel: +58 4 4635911Fax: +58 4 4635911E-Mail:

Venezuela & N. AntillesMaracaibo Rotork Company Tel: +58 61 579315/492611Fax: +58 61 579315E-Mail:[email protected]

Venezuela & N. AntillesPuerto La Cruz Rotork CompanyTel: +58 281 268 0759 Fax: +58 281 266 3554E-Mail:

VietnamAgentTel: + 84 8 84 62525Fax: + 84 8 8423218E-Mail: [email protected]

YemenAgent Tel: +967 1 272988/272956Fax: +967 1 271890/274148E-Mail:[email protected]


As we are continually developing our products,the design of Rotork actuators is subject tochange without notice. The latest product andtechnical information is available at ourwebsite: www.rotork.com.The name Rotork is a registered trade mark. P

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This manual is for use withIQ actuator serial number


Date post:	23-Sep-2018
Category:	Documents
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