“OPERATIONS AND MAINTENANCE INSTRUCTIONS”

February 24, 2012

“OPERATIONS AND MAINTENANCE INSTRUCTIONS”

FURNISH ANSI BUTTERFLY VALVES

CITRUS PUMP STATION, CRAFTON HILLS PUMP STATION, AND CHERRY VALLEY PUMP STATION EAST BRANCH EXTENSION PHASE II

CONTRACTOR PACIFIC INFRASTRUCTURE CORPORATION 435 BOULDER COURT, SUITE 200 PLEASANTON, CA 94566 925-249-0011 MANUFACTURER DeZURIK 250 RIVERSIDE AVE NORTH SARTELL, MN 56377 320-259-2000 LOCAL SUPPLIER FRANK A OLSEN COMPANY PO BOX 2009 LIVERMORE, CA 94551-2009 925-961-8888 CONTRACTOR PO: 1073-5693 FACTORY ORDER: WO 770266 & 770548, SO 611812, 611813, Rotork B43422

Specification No. 10-16

Contract No. C51422

DWR File No. V116-119B

Project Name & Location:

Citrus Pump Station, Crafton Hills Pump Station, and Cherry Valley Pump Station East Branch Extension Phase II

Contractor’s Name Pacific Infrastructure Corporation

Description/Loc./Application Furnish ANSI Butterfly Valves

Ref: Section 11283 ANSI Valve Actuators

Bid Item No. 1, 2, 3, 4, 5, 7

1

TABLE OF CONTENTS

Document No. Page Title Page 1– Table of Contents 2 Data Sheets – Bid item 1 - Electric Actuator for use with 54" ANSI Butterfly Valve 3– Bid item 2 - Manual Gear for use with 20" ANSI Butterfly Valve 7– Bid item 3 - Manual Gear for use with 18" ANSI Butterfly Valve 5– Bid item 4 - Manual Gear for use with 16" ANSI Butterfly Valve 6– Bid item 5 - Manual Gear for use with 14" ANSI Butterfly Valve 7– Bid item 7 - Spare Parts for Manual Actuator 8– - Spare Parts for Electric Motor & Gearbox 9 Drawings

J49192 54" ANSI Butterfly Valve with Electric Actuator 10J49181 18 & 20" ANSI Butterfly Valve with Manual Actuator 11J49201 16” ANSI Butterfly Valve with Manual Actuator 12J49186 14” ANSI Butterfly Valve with Manual Actuator 13J49191 Connecting Parts FUW BHP Butterfly Valves 14

PUB-IW5R WL Rotork IW5R Manual Actuator Outline 15B4342201-04 Rotork IQ12 Electric actuator with IW8 Worm Gear 16

IW5A672 Rotork IW5R Manual Actuator Assembly 17IW8A502 Rotork IW5R Manual Actuator Assembly 18DOC1522 IQ Terminal Block 19DOC755-2 Rotork IQ Electric Actuator Assembly 20

– British Standards Cross Referenced to ASTM 22– Lubrication Drawing 23

43824-10 Nameplate Drawing 24– Disconnect Drawing 25

3010-000-08 Actuator Wiring Diagram 26RWS300 Remote Wiring Diagram 27

Motor Data B43422-1 Motor Data Sheet 28

– Electrical Motor Data 29– Relay Data 30 Operations & Maintenance Manuals

DP00038 Rotork Gearboxes 31DP00091 Rotork IQ Actuators 43

Additional Data Catalog Cuts

E110E IQ Brochure 91– IW Brochure 123– Disconnect Brochure 125– Disconnect Cut Sheet 126– Switch Cut Sheet 127

RG-IW-002 Worm Gear Instructions 129CA15 Limit Switch Mounting Details 135

– MSDS Sheets 136– IQ Actuator Recommended Spare Parts 147– IW Gearbox Recommended Spare Parts 148– Safety Precautions 149

2

Submittal Data Sheet Date: 10/05/11 PACIFIC INFRASTRUCTURE CORPORATION P.O. 1073-5693 2134-C RHEEM DRIVE FACTORY ORDER NO 770548 PLEASANTON, CA 94588 FACTORY SALES ORDER NO 611813 Citrus Pump Station, Crafton Hills Pump Station, and Cherry Valley Pump Station East Branch Extension Phase II Fact. ITEM

BID ITEM

QTY

DESCRIPTION PART NO. 9612529

1 1 2 ROTORK ELECTRIC ACTUATOR WITH WORM GEAR FOR USE WITH 54” BHP BUTTERFLY VALVE

• ROTORK ELECTRIC ACTUATOR MODEL IQ12FA10B4, THROTTLING SERVICE, PART NO. 1394663 • ROTORK IW8R-720:1 WORM GEAR OPERATOR • LOCKING DEVICE FOR OPEN AND CLOSED POSITION Fact. ITEM

BID ITEM

QTY


2 1 2 DISCONNECT SWITCH • ROTORK DISCONNECT SWITCH • UNFUSED • NEMA 4X • FIBERGLASS • 16 AMP TAGS CS-BFV-9 CS-BFV-10 WEIGHT (LBS) MOTOR 70 WORM GEAR 489 TOTAL 559

3


BID ITEM

QTY


1 2 7 ROTORK IW5 MANUAL GEAR OPERATOR FOR USE WITH 20” BHP BUTTERFLY VALVE

• ROTORK IW5 MANUAL GEAR OPERATOR • 120:1 GEAR RATIO • FA16 BASE • 24" HANDWHEEL WITH 2" SQUARE NUT • WESTLOCK 2007X LIMIT SWITCH TAGS CS-BFV-3 CS-BFV-4 CS-BFV-5 CS-BFV-6 CH-BFV-33 CH-BFV-35 CH-BFV-37 WEIGHT (LBS) WORM GEAR 185

4


BID ITEM

QTY



• ROTORK IW5 MANUAL GEAR OPERATOR • 120:1 GEAR RATIO • FA16 BASE • 24" HANDWHEEL WITH 2" SQUARE NUT • WESTLOCK 2007X LIMIT SWITCH TAGS CS-BFV-7 CS-BFV-8 WEIGHT (LBS) WORM GEAR 128

5


BID ITEM

QTY



• ROTORK IW5 MANUAL GEAR OPERATOR • 120:1 GEAR RATIO • FA16 BASE • 24" HANDWHEEL WITH 2" SQUARE NUT • WESTLOCK 2007X LIMIT SWITCH TAGS CV-BFV-21 WEIGHT (LBS) WORM GEAR 128

6


BID ITEM

QTY



• ROTORK IW5 MANUAL GEAR OPERATOR • 120:1 GEAR RATIO • FA16 BASE • 24" HANDWHEEL WITH 2" SQUARE NUT • WESTLOCK 2007X LIMIT SWITCH TAGS CS-BFV-1 CS-BFV-2 WEIGHT (LBS) WORM GEAR 128

7


BID ITEM

QTY


6 7 12 SPARE PARTS SET FOR ROTORK IW5A672 WORM GEAR ACTUATORS

PART NO. DESCRIPTION QUANTITY ITEM SPARE PARTS FOR ROTORK IW5A672 WORM GEARS – SEE DRAWING NO. IW5A672

0096-24N O-RING 8 1 0245-30N O-RING 1 2 0295-30N O-RING 1 3 0595-30N O-RING 2 4 0795-30N O-RING 1 5 0995-30N O-RING 1 6 1395-30N O-RING 1 7 2395-30N O-RING 1 8

HSM10X25SS-P HEXAGON SET SCREW 8 14 HSM16X35SS HEXAGON SET SCREW 4 15

HSM20X80EHTZP HEXAGON SET SCREW 2 16 NL10 NORDLOCK WASHER 8 32

NM20ZP HEX NUT 2 33 SCM10X25SS17/4PH SOCKET HEAD CAP SCREW 12 35

SCM10X45ZP SOCKET HEAD CAP SCREW 8 36 SEALANT SILICONE SEALANT 0.10 L 37

NOTE: NO SPECIAL TOOLS REQUIRED

8


BID ITEM

QTY


3 7 2 SPARE PARTS SET FOR ROTORK ELECTRIC ACTUATOR

PART NO. DESCRIPTION QUANTITY ITEM

SPARES FOR ROTORK IQ12FA10 B4 ELECTRIC ACTUATOR – SEE DRAWING NO. DOC755

71-130 Fuses 2 N/A 71-659 Fuses 2 N/A 71-656 Fuses 2 N/A

Mod. 11A Maintenance Kit 1 N/A Mod. 1H Resolver PCB 1 69 Mod. 6G Main PCB 1 82 Mod. 2C (B4) - Drive Bushing 1 56 Mod. 6D Contactor Assembly 1 78

SPARE PARTS FOR ROTORK IQ8R720 WORM GEAR – SEE DRAWING IW8A502R

0195-30N O-RING 8 1 0395-30N O-RING 1 2 0495-30N O-RING 1 3 0845-30N O-RING 2 4 0995-30N O-RING 1 5 1895-30N O-RING 1 6 1943-57N O-RING 1 7 2593-57N O-RING 1 8

HSM16X35SS-P HEXAGON SET SCREW 8 14 HSM20X100EHTZP HEXAGON HEAD SET SCREW 8 15

IBIB63 NAMEPLATE 1 16 NNM30ZP-T LOCK NUT 2 32

NL12SS NORDLOCK WASHER 4 33 NL16SS NORDLOCK WASHER 16 35 NL20SS NORDLOCK WASHER 8 36

SCM20X80ZP SOCKET HEAD CAP SCREW 8 42 SCM30X100SPFT SOCKET HEAD CAP SCREW 2 43

SILICON SILICON SEALANT 0.10L 44

NOTE: NO SPECIAL TOOLS REQUIRED

9

10

11

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TAGS FOR -18" VALVES: CS-BFV-7, CS-BFV-8 -20” VALVES: CS-BFV-3, CS-BFV-4, CS-BFV-5, CS-BFV-6, CH-BFV-33, CH-BFV-35, CH-BFV-37

12

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Line

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TAG: CV-BFV-21

13

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Line

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TAG: CS-BFV-1, CS-BFV-2

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TAGS: 18” VALVES CS-BFV-7 CS-BFV-8 20” VALVES CS-BFV-3 CS-BFV-4 CS-BFV-5 CS-BFV-6 CH-BFV-33 CH-BFV-35 CH-BFV-37 54” VALVES CS-BFV-9 CS-BFV-10

DETAILS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE FOR UP TO DATE DETAILS VISIT www.rotork.com

DRAWING No. Rotork Gears Americas1811 BrittmooreHoustonTexas77043U.S.A.

DRAWN

DATE

ISSUE

08/03/2011

RJONES

PUB-IW5R WL

A

IW5R 120:1 FA14 INPUT, FA14 OUTPUT, 24" HANDWHEEL WITH 2" NUT

WITH WESTLOCK 2007X SWITCHBOX

178

7.01

"

1204.72"

O 28511.22"

512.02"

1435.64"

1706.70"

1375.40"

136

5.35

"

642.50"CRS

O19

07.

48"

1124.42"

MAX STEM ENTRY

1766.94"

33513.20"

50 1.97

"

WESTLOCK 2007X

O24" HANDWHEEL

2" SQUARE NUT(WELDED TO HUB)

FA14INPUT

FA14 OUTPUT4 HOLES X 5/8-11UNCEQUALLY SPACED AS SHOWN ON O5.50" P.C.

O30 [1.18"]INPUT SHAFT

MAX BOREO76 [3"]

652.57"

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TAGS: CS-BFV-1 CS-BFV-2 CS-BFV-3 CS-BFV-4 CH-BFV-33 CH-BFV-35 CH-BFV-37 CS-BFV-5 CS-BFV-6 CV-BFV-21 CS-BFV-7 CS-BFV-8

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CS-BFV-9, CS-BFV-10

EXEECO LTD C 2010THIRD ANGLE PROJECTION

DO NOT SCALE

MATERIAL:-

PROJECT:-

SCALE

(A3)

DRAWN:-

CHECKED:-

ISSUE

A

ALTERATIONS

ORIGINAL ISSUE

HEATTREATMENT

PROTECTIVETREATMENT

SUITABLY PROTECTFOR STORAGE

ROTORK GEARSREGINA HOUSERING ROADBRAMLEYLEEDSWEST YORKSHIRE

IW5A672

IW5A672AWWA C504-06-IW5

J. PRIESTLEY 07/04/2010

2010 AWWA C504-06 120:1 IW5 ABOVE GROUND SERVICE GEARBOX.

WEIGHT: 53.92 kg 1 : 10C.F. 09/04/2010

NOTES:1. ALL DIMENSIONS IN MM

SCRAP VIEW INPUT1:5

11

9

10

35

14

15

16 33

35

36

32

30

31

1

2

3

4

5

6

7

8

13

18

19

20

21

17

25

24

27

28

29

26

22

38

10

4

35

11

O 140.005.512" PC

O95.3295.273.753"3.751"

SPIGOT RECESS

4 HOLES O16.50[0.650"]+0.50[0.020"]THROUGH

EQUISPACED AS SHOWNFA14 OFF CENTRES

O29.9829.951.180"1.179"

ITEM PART NUMBER DESCRIPTION MATERIAL QTY1 0096-24N O RING NITRILE 82 0245-30N O-RING NITRILE 13 0295-30N O-RING NITRILE 14 0595-30N O-RING NITRILE 25 0795-30N O-RING NITRILE 16 0995-30N O-RING NITRILE 17 1395-30N O-RING NITRILE 18 2395-30N O-RING NITRILE 19 6005 DEEP GROOVE BALL BEARING STEEL 110 6206 DEEP GROOVE BALL BEARING STEEL 211 7205B ANGULAR CONTACT BALL BEARING STEEL 212* CLX2 GREASE RENOLIT CLX2 1.2 kg13 FL17 INPUT FLANGE SG IRON BS EN 1563 EN-GJS-450-10 114 HSM10X25SS-P HEXAGON SET SCREW STAINLESS STEEL GRADE A4/80 815 HSM16X35SS HEXAGON SET SCREW STAINLESS STEEL GRADE A4/80 416 HSM20X80EHTZP HEXAGON SET SCREW SCREW STEEL 12.9 STRENGTH GRADE 217 IB1B64 NAMEPLATE ALUMINIUM TO BS1470 GRADE H4A 118 IR1A129 INPUT SHAFT & GEAR 3:1 STAINLESS STEEL BS970 431S29T 119 IR1B12/2 OUTPUT GEAR STEEL BS970 605M36T 120 IR1D05 GEARCASE CAST IRON TO BS 1452 GRADE 250 121 IW3A188 LABEL - SHCS/NORDLOCK WASHER SELF ADHESIVE PAPER 122 IW5A546 FA14 INPUT FLANGE SG IRON BS EN 1563 EN-GJS-400-15 123 IW5A565 OUTPUT SLEEVE STEEL TO BS 970 GRADE 080M40 (EN8) or

GB699-88 GRADE 451

24 IW5A567 INDICATOR PLATE MILD STEEL 125 IW5A581/1/2 WORM QUADRANT BS1400 HTB3 / BS EN 1982 CC7625/ASTM

B584 UNS C86300 (MANGANESE BRONZE)1

26 IW5A665 GEARCASE SG IRON BS EN 1563 EN-GJS-450-10 127 IW5C102/2 WORM SHAFT LH STEEL BS970 605M36T 128 IW5C12/1 END CAP CAST IRON TO BS1452 GRADE 17 OR STEEL

TO BS970 GRADE 070M201

29 IW5D06/3 BASEPLATE CAST IRON BS EN 1561 EN-GJL-250 130 K8X7X40 KEY 8 X 7 X 40 KEY STEEL TO BS 4325 PART 1 131 K8X7X40SS KEY 8X7X40 SS STAINLESS STEEL GRADE A4 132 NL10 NORDLOCK WASHER STEEL ZINC PLATED 833 NM20ZP HEX NUT STEEL BS3692 GRADE 8 (ZINC PLATED) 234* PA24 PAINT PE3 PRIMER PAINT PE3 0.20 L35 SCM10X25SS17/4PH SS SOCKET HEAD CAP SCREW 17/4PH STAINLESS STEEL TO BS970 GRADE 17/4 PH 1236 SCM10X45ZP SOCKET HEAD CAP SCREW STEEL GRADE 12.9 ZINC PLATED 837* SEALANT SILICONE SEALANT SILICONE 0.10 L38 T0A11 SPACER STEEL BS970 070M20 1

23

ISOMETRIC

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TAGS: CS-BFV-1 CS-BFV-2 CS-BFV-3 CS-BFV-4 CH-BFV-33 CH-BFV-35 CH-BFV-37 CS-BFV-5 CS-BFV-6 CS-BFV-7 CS-BFV-8 CV-BFV-21

EXEECO LTD C 2010THIRD ANGLE PROJECTION

PROJECT:-

SCALE

(A3)

DRAWN:-

CHECKED:-

ISSUE

A

ALTERATIONS

ORIGINAL ISSUE

HEATTREATMENT

PROTECTIVETREATMENT

SUITABLY PROTECTFOR STORAGE

ROTORK GEARSREGINA HOUSERING ROADBRAMLEYLEEDSWEST YORKSHIRE

IW8A502

IW8A502AWWA C504-06 IW85

J DODD 09/04/2010

AWWA C504-06 720:1 IW85 GEARBOX.

WEIGHT: 241.86 kg 1 : 14C FLESHER 09/04/2010

UNLESS OTHERWISE SPECIFIED:1. ALL DIMENSIONS IN MM

24

34

37

9

10

15

14

32

39

40

41

41

42

43

34

36

35

36

30

31

3

4

4

5

6

7

8

13

16

17

19

20

21

22

28

26

25

29

18

23

11

11

SCRAP VIEW INPUT1:6

4 HOLES O16.50[0.650"]+0.50[0.020"] THROUGHEQUISPACED AS SHOWN FA14 OFF-CENTRES

O95.3295.273.753"3.751"

SPIGOT RECESS

O 140.005.512" PC

O30.0029.951.181"1.179"

UNLESS OTHERWISE SPECIFIED:1. ALL DIMENSIONS IN MM

1

REF DESCRIPTION MATERIAL QTY

1 O RING NITRILE 8

2 O-RING NITRILE 1

3 O-RING NITRILE 1

4 O-RING NITRILE 2

5 O-RING NITRILE 1

6 O-RING NITRILE 1

7 O-RING NITRILE 1

8 O-RING NITRILE 1

9 DEEP GROOVE BALL BEARING STEEL 1

10 DEEP GROOVE BALL BEARING STEEL 2

11 ANGULAR CONTACT BEARING - WESTERN STEEL 4

12* GREASE RENOLIT CLX2 6.5 kg

13 INPUT FLANGE CAST IRON BS EN 1561 EN-GJL-250 1

14 HEXAGON SET SCREW STAINLESS STEEL GRADE A4/80 8

15 HEXAGON HEAD SET SCREW STAINLESS STEEL GRADE A4/80 8

16 NAMEPLATE STAINLESS STEEL 304 1

17 SPACER MILD STEEL TUBE 2.25" OD x 14 SWG 1

18 INPUT SHAFT & GEAR 12:1 STAINLESS STEEL BS970 431S29T 1

19 OUTPUT GEAR SG IRON BS EN 1563 EN-GJS-700-2 1

20 GEARCASE CAST IRON TO BS1452 GRADE 250 1

21 LABEL - SHCS/NORDLOCK WASHER SELF ADHESIVE PAPER 1

22 BASEPLATE CAST IRON BS EN 1561 EN-GJL-250 (CASTING E-IW8A199)

1

23 AWWA WORM SHAFT STEEL BS970 817M40V 1

24 GEARCASE SG IRON BS EN 1563 EN-GJS-400-15 1

25 END CAP SG IRON BS EN 1563 EN-GJS-400-15 1

26 INPUT FLANGE SG IRON BS EN 1563 EN-GJS-450-10 1

27 OUTPUT SLEEVE STEEL TO BS 970 GRADE 080M40 (EN8) or GB699-88 GRADE 45

1

28 INDICATOR PLATE MILD STEEL PLATE 1

29 WORM QUADRANT BS1400 HTB3/BS EN 1982 CC7625/ASTM B584 UNS C86300 (MANGANESE BRONZE)

1

30 KEY 12X8X55 KEY STEEL TO BS 4325 PART 1 1

31 KEY 8X7X55 SS STAINLESS STEEL 1

32 LOCKNUT STEEL BS3692 GRADE 8 ZINC PLATED 2

33 NORDLOCK WASHER STAINLESS STEEL GRADE 316 4

34 NORD-LOCK WASHER STAINLESS STEEL 316 16

35 NORDLOCK WASHER STEEL ZINC PLATED 8

36 NORDLOCK WASHER STAINLESS STEEL 8

37 OLITE BUSH OIL IMPREGNATED BRONZE 1

38* PAINT PE3 PRIMER PAINT PE3 0.40 L

39 RIVET 4 X 3/16" STAINLESS STEEL GRADE A2 2

40 SOCKET HEAD CAP SCREW STAINLESS STEEL GRADE A4/80 4

41 SOCKET HEAD CAP SCREW STAINLESS STEEL GRADE A4-80 8

42 SOCKET HEAD CAP SCREW STEEL GRADE 12.9 ZINC PLATED 8

43 SOCKET HEAD CAP SCREW STEEL GRADE 12.9 ZINC PLATED 2

44* SILICONE SEALANT SILICONE 0.10 L

33

ISOMETRIC27

2

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Material & Spec.

Date

B

A

1 432

B

Do NotScale

Projection

Telephone (585) 328-1550Fax (585) 328-5848

http://www.rotork.com

Rochester, NY 14624Rotork Controls Inc

Issue No Sheet No

of 1Part Number

Treatment

Scale

CheckedDrawn

Title

Issue Date Initials Modification Details

PRE-PRODUCTION ISSUEINDICATED WITH LETTER.

PRODUCTION ISSUEINDICATED WITH NUMERAL

01220401 RAR First Issue.

N/A01/22/2004

N/A

CUSTOMER SIDE OF IQ TERMINAL BLOCKR.RIOCH TLW

01DOC1522 1

1:1

POWER TERMINALSM5 x 0.8p x 6.5mm FULL THREAD

CONTROL TERMINALSM4 x 0.7p x 6mm FULL THREAD

19

1

2

3 4

5

6

78

9

1011

1213

1415

1617

18

19

20

21

22

2324

25 26

27

28

29

30

31

32

33

34

35

36

37

38

39

41

4243

44

45

46

47

48

49

5049

5152

53

5455

56 57

58

59

60

6061

6263

64

65

66 6768

69

70

71

72

73

74

75

7677

78

79

80

8182

83

Publication Number ‐ Date of Issue 12/08

Please contact Rotork when ordering parts.Some parts may only be supplied in modules,containing a group of parts.

Rotork IQ MKII Size 2 Actuator

2DOC755

1 of 2Sheet20

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Please contact Rotork when ordering parts.Some parts may only be supplied in modules,containing a group of parts.

IQ MKII Size 2 ActuatorItem Number Description

1 Handwheel2 Oilseal3 Ball Bearing4 O Ring5 Handwheel Retainer6 O Ring7 Spring Retaining Ring8 Clutch Spring9 Centre Column10 Sliding Coupling11 Dowel Pin 12 Wormwheel13 Yoke14 Bevel Gear15 Battery Plug16 O Ring17 Battery Retainer/ Removal Strap18 Plug19 Spring Hand Auto20 Jack/Finger Hand Auto21 O Ring22 Hand Auto Lever23 Screw24 Transfer Bush Sleeve25 Piezo Sensor26 O Ring27 Thrust Plate28 Shim29 Silicone Pad30 Bearing Thrust Plate31 Retainer Motor Loom32 Screw Hex33 Ball Bearing34 Oil Seal35 Locknut Fuji36 Wormshaft37 Shroud Wormshaft38 Ball Bearing39 Motor Shaft40 O Ring41 Rotor & Stator42 Motor Cover43 Cap Screw44 Terminal Bung45 Terminal Bung Retainer46 Power Screen47 O Ring48 Terminal Cover

2 of 2Sheet

Publication Number ‐ Date of Issue 12/08

2DOC755

Item Number Description49 O Ring50 Ball Bearing51 Bearing Retainer52 Bearing Ring53 Thrust Base54 Washer55 Set Screw56 Drive Bush57 Screwed Ring58 Base Ring59 Cap Screw60 Plug61 Spring Hand Auto62 Jack / Finger Hand Auto Finger63 O Ring64 Hand Auto Lever65 Screw66 Shroud Bevel Shaft67 Oil Seal68 Resolver Shaft69 PCB Resolver70 Washer71 Pan Screw72 Moulded Magnetic Ring73 Bevel Shaft Spring74 Pozi Pan Screw75 Transformer & PCB76 Nut77 Chassis78 ABB Contactor79 Cap Screw80 Cap Screw81 Relay Board82 Main PCB & Option Boards83 Electronics Cover

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British Standards for Material

Cross Referenced to ASTM

22

23

al.germano

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SEE LUBRICATION SCHEDULE

al.germano

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2.C.3 - 98

al.germano

Text Box

Capacity is .63 pints

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0

0 1"

10 20 30mm

Make from Part No:Refer to Rotork Spec:

Job No.

A3

A

1 4 6 87532

D

E

C

B

Do NotScale

MANUFACTURING DIMENSIONS SPECIFIED IN MILLIMETRES.UNSPECIFIED DIMENSIONAL TOLERANCES:-

MACHINED = ±0.25mm, CAST = ±0.8mm, MOULDED = ±0.25mm, ANGULAR = ±1/2°UNSPECIFIED MACHINED RADII = 0.8mm MAXIMUM.SURFACE FINISH INDICATED IN MICROMETRES.ISO GEOMETRICAL TOLERANCING SYSTEM TO BS308 PART 3.THREAD TOLERANCES- METRIC TO BS3643 CLASS 6H+6g, UNIFIED TO BS1580 CLASS 2A+2B.PART NUMBER TO BE PERMANENTLY MARKED ONTO COMPONENT AT POSITION MARKED THUS:-REMOVE ALL BURRS AND SHARP EDGES.

Projection Ref for 1:1 Scale

Telephone 01225 -733200Telefax 01225 -333467mail @ rotork.co.ukhttp://www.rotork.com

Bath, England BA1 3JQ.Rotork Controls Limited

Issue No Sheet No

of 1Part Number

Material & Spec.

Scale

CheckedDrawn

Title

Issue Date Eng.Chg NoInitials Modification Details

_ 43756_

ALUMINIUM BS1470 NS4

NAMEPLATE FM ROCHESTER (USA MANF)M WILLIAMS PGC

1043824 1

1:1

Certified ProductNo modifications permittedwithout the approval of the

Certification Engineer9 290410 PMJ EC3539 CERT STAMP ADDED

Wiringdiagram

currentIndication

Nominal motorMotor supply

LubricationMotor rating

NEMA/Enclosure

301205VdcVacAmps

kg

Foreign Patents pendingBRITISH PATENT No.GB 2327763

Actuator weightcontacts

Amp

rpm

Torque max.

Speed

typeActuator

Serial No.

Temp.code

6/WT

Model IQFM

ROTORK CONTROLS INC.675 MILE CROSSING BLVD.ROCHESTER, NY 14624, USA

basesize

Year of manufacture

kW min.

www. .com

47.0

0

41.0

0

32.0

0

22.5

0

4.50

9.00

7.50 15.00

10.50

5.00

28.00

21.5

0

13.50

18.0

026

.00

30.5

0

35.0

0

39.5

0

9.00

13.5

0

2.00

4.50

55.7

05.

00

20.0043824-10

PRODUCT OFTHE USA

FMAPPROVED

10 041110 PMJ EC3677 BARCODE SPACE ADDED.TEXT REARRANGED

SPACE FOR SERIALNUMBER BARCODE

START LINE FOR SERIALNUMBER BARCODE

Service585 247 2304

coupling

Nm

24

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Disconnect

switchesNon-fusibleEnclosed

Low Voltage Products & Systems 18.39ABB Inc. • 888-385-1221 • www.abb.us/lowvoltage 1SXU000023C0202

18

eOT16_, eOT32_ (enclosure size 1)

2007.87

1887.40

1766.93

883.46

732.87

1465.75

Ø 4.5 0.18 103.5

4.0734.51.36

1385.43

40.31.59

30.51.20

3/4 " 1 "

1887.40

mmin

3/4 " 1 "

EOT32U_ , EOT45U_

200.79

100

140

152

50

76

7,40

4,5

5,98

1,97

161,46,35

1525,98

inmm

5,51

2,99

0,18

0,29

3,9434,51,36

813,19

115,54,55

ONI

O O

FF

Handle OHB 2AJ Knock-outs on top and bottom

301,18

20

1/2 "3/4 "

0,79

Knock-outs M20

M25

0,09R2,25

2007.87

1887.40

1766.93

883.46

732.87

1465.75

Ø 4.5 0.18 103.5

4.07451.77

148.55.84

40.31.59

30.51.20

3/4 " 1 "

1887.40

mmin

3/4 " 1 "

EOT32U_ , EOT45U_

200.79

eOT Enclosed switchesApproximate dimensionseOT16_ - eOT45U

eOT45U_ (enclosure size 2 with selector handle)

eOT45U_ (enclosure size 2 with pistol grip handle)

25

Larkey_M

Line

Larkey_M

Text Box


26

Larkey_M

Text Box


STANDARD IQ/IQT REMOTE CONTROL CIRCUITRY (24VDC)

A4

ROTORK CONTROLS LTDBATH, BA1 3JQENGLAND

www. .comDocument No

Document Title:

This is an Associative Document that needs to be read inconjunction with the appropriate Rotork Wiring Diagram.

ROTORK CONTROLS INCROCHESTERNY 14624, USA

Issue No

FORM A

FORM C

FORM F

FORM E

FORM D

FORM B

-VE

CONT

ROLS

UP

TOCO

NTRO

LS 6

0V T

O

24V

DC +

VE

EMER

GEN

CY S

HUTD

OW

N

60V

AC O

R DC

120V

AC

INTE

RNAL

SUP

PLY

COM

MO

N FO

R RE

MO

TECO

MM

ON

FOR

REM

OTE

INTE

RNAL

SUP

PLY

OPEN/CLOSE PUSH TO RUN CONTROL(LOCAL CONTROL REMAINS SELF MAINTAINED)

OPEN/CLOSE MAINTAINED CONTROLWITH MID TRAVEL REVERSAL

OPEN/STOP/CLOSE MAINTAINED CONTROL

CLO

SE

Close

To external supply or terminal 5(see 'Note:' above)

MAI

NTAI

N

OPE

N

#

#

#

#

#

THE INFRA RED SETTING TOOL ENABLES ALL CONFIGURABLEACTUATOR SETTINGS TO BE MADE.

BEFORE PUTTING THE ACTUATOR INTO SERVICE, IT MUST BEINSTALLED AND COMMISSIONED IN ACCORDANCE WITHPUBLICATION E170E (IQ) or E175E (IQT) INSTALLATION ANDMAINTENANCE INSTRUCTIONS.UNLESS SPECIFIED WITH ORDER, THE ACTUATOR ISDESPATCHED WITH DEFAULT SETTINGS AS LISTED INPUBLICATION E170E (IQ) or E175E (IQT).

FOR IQ/IQT CONTROL AND MONITORING FACILITIES, REFER TOPUBLICATION E120E.

NOTE:ACTUATOR REMOTE CONTROL SIGNALS MAY BE INTERNALLY OREXTERNALLY SUPPLIED.

INTERNALLY SUPPLIED:FIT LINK '#' AS SHOWN AND CONNECT REMOTE CONTROLCONTACTS TO INTERNAL SUPPLY ON TERMINAL 5.

EXTERNALLY SUPPLIED:CONNECT CONTROL CONTACTS TO EXTERNAL SUPPLY LIVE/+VE.CONNECT SUPPLY ZERO/-VE AS FOLLOWS:- TO TERMINAL 36 & 31 FOR SUPPLIES UP TO 60VAC or DC TO TERMINAL 40 & 32 FOR SUPPLIES UP TO 120VAC

FOR CONTROL FORMS D & E, LINK '#' MUST BE FITTED.CONNECT ZERO/-VE AS INDICATED ABOVE.

CUSTOMER CONNECTION FORREMOTE CONTROL

4 36 40 33 34 35 5 25

4 36 40 33 34 35 5 25

4 36 40 33 34 35 5 25

4 36 40 33 34 35 5 25

4 36 40 33 34 35 5

4 31 32 33 34 35 5 25

25

TWO WIRE CONTROL, ENERGISE TO OPENDE-ENERGIZE TO CLOSE.(CONFIGURE FOR OPEN PRIORITY)CUSTOMER TO LINK 5 - 33

TWO WIRE CONTROL, ENERGISE TO CLOSEDE-ENERGIZE TO OPEN(CONFIGURE FOR CLOSE PRIORITY)CUSTOMER TO LINK 5 - 35

EMERGENCY SHUT-DOWN CIRCUIT.THE ESD CIRCUIT CAN BE ADDED TO ANY OF THE CONTROLCIRCUITS SHOWN ABOVE.AN ESD SIGNAL APPLIED TO THE ACTUATOR WILL OVERRIDEANY EXISTING OPEN OR CLOSE CONTROL SIGNAL.THE DEFAULT ESD CONFIGURATION IS "STAY PUT", DERIVEDFROM A N/O CONTACT (SIGNAL APPLIED).FOR OTHER CONFIGURABLE ESD SETTING OPTIONS, REFER TOPUBLICATION E170E (IQ) or E175E (IQT) INSTALLATION ANDMAINTENANCE INSTRUCTIONS.

To external supply or terminal 5(see Note:' above)



Close Open

Open Stop

Close Open

Close Open

Open Close


ESDswitch

#

#

(stayput)To external supply or terminal 5(see 'Note:' above)

2RWS30027

Larkey_M

Text Box


CUSTOMER DATA VALVE DATA

ACTUATOR DATA

Conduit 2:

MOV Tag No.'s: 1394663Shop Drawing:

Project:

Consultant:

CITRUS PS SACRAMENTO, CA

B4342201

Paint Spec.:

Actuator/Gear Weight:

Enclosure:

Rated Torque:

Wiring Diagram:

559 lbs

60 lbft

Class:

12:1 SIDE

Type:

Handwheel Type:

Cust. Part Number:

Base:

Operating Temp.:

Stall Torque Range:

db 3111794

IQ12FA10B4

84 - 144 lbft Lubrication:

Conduit 1 & 3:

Conduit 4:

3010-000

NEMA 4/6

Size:

-30C TO +70C

None

ASA 1.5''

HYDRA GB

P.O. No.: 770548

P.O. Item: 1394663

FA10

Date:

Line:

DEZURIK INC. Make:

Contract Eng.:

ASA 1.0''

**MI0R00208

B43422 1

Model No.:

Name:

Job Number

10/04/2011

IQ Electric Motor Actuator Data Sheet

MOTOR DATA

*Nominal HP and Run Load Amps are at 1/3 full rated torque output.

SECONDARY GEARBOX DATA

** Beige paint to be Federal Standard 595 Color(January 2008) No. 26521

0.34

Model Number/Size:

*Nom. Motor HP:

Operating Time: 251 sec

5.35

1.7

1.2 A

Ratio:

IW8R

Insulation Class/Duty:

Rotork Gears

Type: Totally Enclosed Non-Ventilated

1Service Factor

Combined Torque:

720:1'

17100 lbft

Locked Rotor Amps:

Rated Load Amps:

Gearbox Base: FA25

*Nominal Load Amps:

480V / 3Ph / 60HzSupply V/Ph/Hz:

Lubrication:

Make:

F / 15 min

Grease

28

Tschid_C

Text Box


Rotork Controls, Inc.

675 Mile Crossing Blvd.

Rochester, New York

14624

Motor Data – B43422

Voltage 480Phases 3Frequency 60Nominal Power ‐ running torque .26 KwNominal Power ‐ locked rotor torque 3.8 KwCurrent ‐ running torque 1.16 AmpsCurrent ‐ locked rotor torque 5.35 AmpsSpeed 43 RPM

29

Rotork Controls, Inc.

675 Mile Crossing Blvd.

Rochester, New York

14624

Relay Data – B43422

Relay Operation Time 300 millisecondsRelay Pickup Voltage 24vdcRelay Drop out Voltage 3vdcRelay Current of Controls 5 mAAuxiliary Device Coils N/A

30

DeZURIK VENDOR INSTRUCTIONS ROTORK IW, MOW, AND MTW RANGE WORM GEARBOXES

Instruction DP00038June 2011

31

Gearbox Installation Manual Rotork Gears IW, MOW, and MTW ranges

! This manual contains important safety information. Please ensure it is thoroughly read and understood before installing the gearbox.

! This manual is produced to enable a competent person to install the gearbox. Onlypersons competent by virtue of their training or experience should install, maintain and repair the supplied gearbox.

! The gearbox weight is recorded on the packaging and on a label attached to the gearbox.

! WARNING Gearbox may present an unbalanced load.

! WARNING With respect to handwheel operation of Rotork gearboxes, under no circumstances should any additional lever device such as a wheel-key or wrench be applied to the handwheel in order to develop more force when closing or opening thevalve as this may cause damage to the valve and/or gearbox or may cause the valve to become stuck in the seated/backseated position.

! WARNING Damage to protective coatings should be correctly rectified and mayinvalidate warranty.

Contents1. Introduction 2. Health and safety3. Storage4. Unpacking5. Handling 6. Installation & maintenance – Worm Combinations7. Installation & maintenance- multi-turn IB & IS range combinations 8. Reference

1. IntroductionUnless otherwise specified the gearbox is supplied assembled. In the case of ¼ turn gearboxes,the gearbox stops have been set to a nominal 90° open and close position.! The IW gearbox stops must be re-set for the stroke of the valve after combinationinstallation.

2. Health and safetyThis manual is produced to enable a competent user to install, operate, adjust and inspect Rotorkgearboxes. Only persons competent by virtue of their training or experience should install, maintain and repair Rotork gearboxes.Work undertaken must be carried out in accordance with the instructions in this and any otherrelevant manuals. The user and those persons working on this equipment should be familiar withtheir responsibilities under any statutory provisions relating to the Health and Safety of their workplace. Due consideration of additional hazards should be taken when using the gearbox with other equipment. Should further information and guidance relating to the safe use of the Rotorkproducts be required, it will be provided on request.

RG-INSTALL-003 Page 1Date 27/08/2009

32

The mechanical installation should be carried out as outlined in this manual and also in accordance with relevant standards such as British Standard Codes of Practice. No inspection or repair should be undertaken unless it conforms to the specific hazardous area certificationrequirements.For maintenance of the actuator, refer to the actuator installation and maintenance manual.

! WARNING: Enclosure Materials. The gearbox enclosure may include cast iron, SG iron,carbon steel or stainless steel.

3. Storage If your gearbox cannot be installed immediately store it in a clean dry place until you are ready to install in situ. Recommended storage temperature range: 0°C to 40°C (32°F – 104°F).

4. UnpackingGearboxes are packed in a variety of configurations depending on size, type and quantity of the consignment.It is the responsibility of the individual unpacking and handling the combination to carry out a risk assessment for the supplied arrangement to ensure safe working. Refer to Section 5 Handling.Packaging material used may include wood, cardboard, polyethylene and steel. Packagingshould be recycled according to local regulations.

5. Handling

! Individual weights for gearboxes are recorded on their respective nameplates

! Only trained and experienced personnel should carry out handling. At all times, safe handling must be ensured.

! Each combination must be assessed to identify all risks associated with handling.

! Gearboxes may present an unbalanced load.

! The gearboxes must be fully supported until full valve shaft/stem engagement is achieved and the gearbox is secured to the valve flange.

! Once connected to the valve, each assembly must be assessed on an individual basis for safe handling/lifting. Never lift the complete combination-valve assembly via the gearbox.

! If it is necessary to lift the gearbox using lifting equipment, certified soft slings are recommended. Damage to protective coatings should be correctly rectified and may

invalidate warranty.


33

6. INSTALLATION OF WORM COMBINATIONS

6.1 Output sleeve removal, machining and refittingGearbox sizes IW12 to IW16 have an output which will be directly machined as specified withorder. All other worm gearbox combinations have a removable output sleeve (1) See Fig. 1. Unless specifically requested at the ordering stage, the output sleeve will be supplied blank andmust be machined to suit the valve shaft.

The sleeve can be easily removed from the top of the gearbox by first removing the indicator/cover plate (3) and output sleeve retaining screws (5). These screws are either serrated under their heads or are fitted with serrated washers (4)

! WARNING: Removing retaining screws will result in loss of control of the valve.

O rings (2) are used to seal the indicator plate, output sleeve and retaining screws. Upon final installation on the valve, these screws must be tightened to the correct torque figures as shownon the label on the underside of the indicator or cover plate.

RetainingScrews

SerratedWashers

Indicator cover

O-rings

Output Sleeve

Fig.1 shows the removal of the output sleeve from the gearbox. See Fig.2 for removing the outputsleeve without damaging the sealing faces.

Before refitting the output sleeve after machining, check that the surfaces marked ‘A’ in Fig.2 are not damaged. Damaged surfaces can break the gearbox seals and cause water ingressor grease leakage. Applying a thin layer of grease to the faces marked ‘A’ will make refitting of the sleeve easier.

As detailed in Fig. 1 and Fig. 2, it is recommended that silicon sealant is used to seal the indicator/cover plate to the output sleeve by applying sealant to the face marked D. Taking care not to apply sealant to the o rings (2) or the sealing faces of the o rings.

Before re-assembly, clean and de-grease the top face of the output sleeve, underside of the indicator/cover plate, and the socket head cap screws. Make a note of the tightening torquerequired for the output sleeve screws on the label on the underside of the indicator plate. Insert the screws and washers into the holes in the indicator/cover plate.


34

It is essential to fit the two part washers the correct way round with the cam faces of the washers joining. Place the o rings over the screw threads and against the indicator plate.

2 Part Washer

Indicator Plate

O-ring

Apply a thin coat of silicon sealant to the top face of the output sleeve. Place the indicator on the output sleeve, with the indictor pointer in the correct orientation if applicable. Engage eachscrew through the indicator and output sleeve into the tappings in the gear quadrant. Fasten the screws evenly. As the screws start to tighten, press down on the indicator plate to extrude anyexcess sealant. Wipe away the excess. Tighten each screw to the recommended torque previously noted.

! WARNING It is absolutely essential to assemble and torque tighten the screwsimmediately after the sealant is applied to the indicator/cover plate and screws. Any delaywill allow the sealant to start to cure. This will result in a flexible joint being formed between the output sleeve and indicator/cover plate. This joint would relax over time, allowing the screws to loosen.

6.2 Mounting to the valve

! WARNING - Ensure the valve is fully supported and capable of accepting increasedweight and change of centre of gravity resulting from the addition of the gearboxcombination.

If the gearbox has been supplied with a handwheel, it is recommended that this be fitted to thegearbox before mounting onto the valve. This will make it easier to rotate the gearing to pick upon the valve stem, either key, flats or square.

1) Ensure gearbox output is in the same relative position as the valve shaft (open orclosed). Gearbox output position can be moved by rotating the input shaft or turning the actuator handwheel.


35

2) Align gearbox baseplate flange square and parallel to valve flange. As shown in Fig. 3, It is recommended that flanges be sealed on assembly with silicon sealant. Grease the output sleeve and the valve shaft.

3) Engage gearbox output sleeve on to valve shaft ensuring valve shaft keyway, square etc is in alignment (if necessary rotate output sleeve– refer to 1)

4) It is essential that the gearbox baseplate is flush with the valve bonnet flange before the mounting screws are tightened. Mounting screws or studs/nuts must be high tensile steel (grade 8.8 or higher). Firmly tighten down fixings onto the valve flange to the torque required. See Table B on page 9.

6.3 Setting the gearbox stops to suit the valve (IW and MOW Only)This procedure should be carried out by the valvemaker/supplier and should be done when thevalve opening and closing operations can be visibly checked. Once installed within the pipe thestops should not be altered without the authorisation of the valvemaker/supplier.The gearbox stops are factory set but require adjusting for optimum valve performance.

If an actuator is to be used to operate the gearbox then the actuator limit and torque switch settings should be set up according to the actuator manufacturer's recommendations. Thegearbox open and closed stop screws should then be set. See Fig. 4. Close the valve, using theactuator where applicable. Use the indicator plate (2) pointer as an indication of position. Loosenthe lock nuts (6) and wind the gearbox closed position stop screw (7) into the gearbox quadrant(5). Back the screw off one turn, then tighten the lock-nut (6) to secure the stop screw. Open the valve with the actuator, and then repeat the process with the open position stop screw.

Note – movement between baseplate (9) and gearcase (8) can occur when operating at nearrated torques. It is recommended that regular maintenance occurs to verify baseplate screws (10)are correctly torqued.


36

6.4 Worm combination maintenance Under normal operating conditions, no maintenance is required for the gearbox. Should the valve be taken out of service for overhaul, the gearbox baseplate may be removed and the lubricant changed using one of the following greases. The baseplate must be sealed using silicone sealant on re-assembly, unless fitted with o-rings. All o rings should be renewed.

IW RANGE Manufacturer Name Temperature Range Fuchs Renolit CL-X2 -60°C to +120°C

MOW RANGE Manufacturer Name Temperature Range

Fuchs Renolit LST 0 -20°C to +120°C

MTW RANGE Manufacturer Name Temperature RangeFuchs Renolit EPLITH 00 -10°C to +120°C

An equivalent extreme pressure lubricant may be used. For extreme temperature applications, please consult Rotork Gears


37

C.F. 07.07.06 issue 3F:\Exeeco\GBOX\ENGINEER\ATEX\Instructions\UPDATE-08-06\Worm Specificationr3.doc

ROTORK GEARS WORM RANGE SPECIFICATION

Component Material Specification

Gearcase Cast Iron or SG Iron, optional Carbon Steel, Stainless Steel.

Baseplate Cast iron as standard, optional SG Iron, Carbon Steel or Stainless Steel.

Input Housing Cast Iron as standard, optional SG Iron, Carbon Steel or Stainless Steel.

End cap Cast Iron or Carbon Steel, optional SG Iron, Stainless Steel.

Worm Gear SG Iron or Aluminium Bronze.

Worm Shaft Carbon Steel as standard, optional Stainless Steel.

Indicator plate Carbon steel, optional Stainless Steel.

Screws High Tensile Steel Metric Standard to BS3692 & 4168 as standard, optional Stainless Steel.

Bearings Angular contact bearings.

Output Sleeve Steel or Cast Iron, optional Stainless Steel or Aluminium Bronze.

Finish PA 24 Grey Primer (Standard).Primer and Enamel Gloss (Optional).Other finishes available on request.

Lubricant CL-X2 (Standard) max temp 120 C: Ignition temperature > 250 CLX-EP2 (High temp) max temp 160 C: Ignition temperature > 250 CNO-TOX EP2 (Food) max temp 204 C: Ignition temperature > 250 CMO2 (Graphite) max temp 120 C: Flash point > 200 CG110 (Nuclear) max temp 150 C: Flash point > 200 CG130 (Nuclear) max temp 150 C: Flash point > 200 CLST 0 (Oil for MTW,MOW) max temp 135 C: Ignition temperature > 250 CEPLITH 00 (MTW) max temp 120 C: Ignition temperature > 250 C

Seals Nitrile (Standard) max temp 150 C: Ignition temperature > 300 CViton (High temp/ Nuclear) max temp 200 C: Ignition temperature > 315 CFluorosilicone (Low temp) max temp 225 C: Ignition temperature > 300 CSilicone sealant max temp 200 C: Ignition temperature > 450 C

Gearbox Detail Gearbox Specification

Gearbox design Life IW: 10000 cycles at one third maximum torqueMTW: 10000 output revolutions at one third maximum torqueMOW: 2 years or 17,520 hours continuous operation

Gears Designed basically to BS721

Gearbox type Indicated on the nameplate

Gearbox ratio Indicated on the nameplate

Maximum output torque Indicated in the Rotork Gears catalogue

Gearbox duty specification Indicated on the nameplate

Nameplate Explosion Marking and Category According to 94/9/EC and indicated on the nameplate

Maximum speed for the input shaft 350 rpm. (IW and MOW must have input reducers fitted and combined ratiosgreater than 720:1 to operate at this speed)

Maximum bending moment on the input flange F10: 200NmF14: 340NmF16: 520NmF25: 1450NmF30: 1580Nm

Maximum operating temperature Indicated on the nameplate

Gearbox weight Indicated on the nameplate

38

C.F. 27.07.10 issue 2 F:\Exeeco\GBOX\ENGINEER\ATEX\Instructions\Worm\Installation Instructions For WormR2.doc

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS FOR EXEECO WORM GEAR OPERATORS

The Rotork Gears Worm Range Specification sheets indicate the materials of construction and information for putting the equipment into service. The gearbox is marked according to 94/9/EC with the temperature class and explosion group on the equipment and this shall be observed when installing and operating the equipment. The user alone is responsible for the appropriate use of the gearbox in consideration of the basic conditions existing at the plant. This range of gearboxes is supplied to suit the order requirements but, unless specifically requested at the ordering stage, the output sleeve will be supplied blank and must be machined to suit the equipment to be operated. IW12 & IW13 gearboxes do not have removable output sleeves and are supplied machined to the customer�s specification. The sleeve can be easily removed from the top of the gearbox by first removing the indicator plate retaining bolts. These bolts are either serrated under head or are fitted with serrated washers. When refitting the bolts, they must be tightened to the correct torque figures as shown under the indicator plate. The recommended tightening torque of screws is also shown in the table below. NOTES FOR MOUNTING TO THE VALVE The following are basic instructions for mounting the gearbox. For detailed information see the Gearbox Installation Manual �RG-INSTALL� and �RG-IW-OS1� 1. The valve spindle must be greased before assembly of the gearbox to the valve. 2. Flanges to be sealed on assembly with silicone sealant. 3. It is essential that the gearbox baseplate is flush with the valve bonnet flange before the mounting screws are tightened. If the gearbox has been supplied with a handwheel, it is recommended that this be fitted to the gearbox before mounting on the valve. This will make it easier to rotate the gearing to pick up the start of a thread or key location. On a keyed valve shaft, once the key and keyway are lined up, the gearbox can be lowered onto the mounting flange and bolted down. On a screwed valve shaft, rotating the handwheel will cause the gearbox to screw itself down the spindle. Once in the correct position it can be bolted down. When bolting the valve to the gearbox we recommend using at least grade 8.8 fasteners, and these MUST be torque tightened dependent upon the grade and size used. If an electric actuator is fitted to the gearbox, a suitable input adaptor will have been supplied. After mounting the actuator to the gearbox, the limit and torque switch settings must be made in accordance with the manufacturer�s instructions. The maximum permitted bending moment on the input adaptor of the gearbox is indicated on the gearbox specification sheet. HANDLING Combined valve, actuator and gearbox must NOT be slung from the gearbox. MAINTENANCE All gear cavities are lubricated and sealed for life and the type of grease and seals used within the gearbox is indicated on the nameplate and shown in the material specification. The required maintenance intervals depend on the respective application and will therefore have to be determined by the user dependent on the conditions of use. Annual inspection of the gearbox is recommended, but under normal operating conditions no maintenance is required for the gearbox, but should the valve be taken out of service for overhaul, the gearbox baseplate may be removed and the grease renewed. The baseplate must be sealed using silicone sealant on re-assembly, unless fitted with an O ring. Below is a table for the recommended tightening of screws. HEXAGON HEAD GRADE 8.8 HEXAGON HEAD GRADE 8.8

WITH NORDLOCK WASHER SOCKET HEAD GRADE 12.9 SOCKET HEAD GRADE 12.9

WITH NORDLOCK WASHER DURLOK GRADE 12.9

SCREW GRADE 12 NUT SCREW SIZE

TORQUE TIGHTNESS (Nm)

TORQUE TIGHTNESS (lbsft)









M4 2 2 3 2 4 3 5 4 M5 5 4 6 4 8 6 10 7 11 8 M6 9 6 10 8 14 11 17 13 19 14 M8 21 15 25 18 35 26 42 31 45 33 M10 41 30 49 36 69 51 83 61 86 64 M12 71 53 86 63 121 89 145 107 152 112 M16 177 131 213 157 299 221 359 265 372 274 M20 346 255 415 306 584 431 701 517 717 529 M24 598 441 718 529 1009 744 1211 893 M30 2006 1480 M36 3508 2587

Note: Once fully torque tightened Durlok fasteners must not be re used on

Nuclear gearboxes

Copy of QC 40-2 NB. All internal cavities within the gearbox must be packed with grease. SPARES Spare parts must be selected from the spare parts lists and a recommended spares holding for 5 years is shown on the spare parts list.

39

C.F. 30.07.10 Issue 3 F:\Exeeco\GBOX\ENGINEER\ATEX\Instructions\Worm\Dismantle & Reassemble WormR3.doc

PROCEDURE FOR DISMANTLING / RE-ASSEMBLY OF WORM GEAR OPERATORS

1. PURPOSE: To provide dismantling / re-assembly instructions.

2. SCOPE: Rotork Gears range of worm gearboxes

3. DEFINITION: Sequence of instructions to dismantle and re-assemble Rotork Gears worm gearboxes.

4. PROCEDURE: Refer to spare parts list for item numbers. For additional information see Documentation.

4.1 Dismantling

4.1.1 If the worm gearbox is fitted with an input reducer see the dismantling instructions for the input reducer to first remove the input reducer.

4.1.2 For output sleeve with o rings, to prevent damage to the o rings (28), slightly loosen ALL the socket head cap screws/Durlok (11) before fully removing the screws.

4.1.3 Fully remove the output sleeve screws (11) from indicator plate (8). 4.1.4 Remove the indicator plate (8) and o rings (28). 4.1.5 Remove the output sleeve (5) where applicable. 4.1.6 Remove the key (20) from the worm shaft (4). 4.1.7 Remove the screwed fasteners (17), which secure the input housing (7) to the gearcase (1). 4.1.8 Remove the input housing from the gearcase. 4.1.9 The worm shaft can sometimes be removed at this stage by unscrewing the worm from the wormwheel

(3). 4.1.10 Remove the screwed fasteners (27) that secure the baseplate (2) to the gearcase. 4.1.11 Remove the baseplate from the gearcase. 4.1.12 Remove the wormwheel (3) from the gearcase. 4.1.13 Remove the screwed fasteners (18) that secure the end cap (6) to the gearcase and remove the end cap. 4.1.14 If the worm shaft was not removed in 4.1.6 then remove the worm shaft complete with the angular

contact bearings (9) and shim (10) where applicable. 4.1.15 Remove bearings from the input housing, end cap or gearcase. 4.1.16 Loosen the lock nuts (16) and remove the stop bolts (15) from the gearcase where applicable.

4.2 Re-assembly

4.2.1 Ensure all parts are free from dirt and bruising 4.2.2 On re assembly, all moving parts should be lightly lubricated with grease before refitting. 4.2.3 Ft the �o� ring (14) to the gearcase. 4.2.4 Fit the bearing(s) in the end cap or within the gearcase, making sure that the bearing is orientated

correctly and packed with grease. 4.2.5 Fit the �o� ring or apply sealant (25) to the end cap and secure to the gearcase with the screwed

fasteners. 4.2.6 Re-fit the worm shaft into the gearcase and locate with the bearing contained by the end cap. 4.2.7 Fit the bearing(s) in the input housing or within the gearcase, making sure that the bearing is orientated

correctly and packed with grease. 4.2.8 Fit the �o� ring (12) to the input housing. 4.2.9 Fit the �o� ring or apply sealant (25) to the input housing and secure to the gearcase with the screwed

fasteners. 4.2.10 Grease the worm shaft and gearcase before refitting the worm wheel. 4.2.11 Re-fit the wormwheel, locating the worm wheel spigot into the bore of the gearcase and ensuring the

gear teeth mesh with the worm shaft. 4.2.12 Fit the lock nuts to the stop bolts and apply sealant to the stop bolts and refit into the gearcase where

applicable. Do not tighten. 4.2.13 Re-pack the gearcase with grease. 4.2.14 Fit the �o� ring or apply sealant (26) to the baseplate and re-fit the baseplate into the gearcase. 4.2.15 Re-secure the gearcase to the baseplate using the existing screws (27) using a diagonal tightening

movement. 4.2.16 Fit the �o ring (13) into the baseplate. 4.2.17 Fit the output sleeve into the gearcase where applicable. 4.2.18 If o rings (28) are used with the output sleeve, position the o rings in the countersink holes of the

output sleeve.

40


4.2.19 Fit the indicator plate. 4.2.20 Loosely fit all of the existing cap screws or Durlok bolts to prevent trapping the o rings (28). Once all

screws have been loosely fit, then torque tighten all screws sequentially. 4.2.21 Re-fit the key to the worm shaft and test the gearbox for free rotation. 4.2.22 For gearboxes with stop bolts rotate the output sleeve to the required position. Adjust the stop bolt and

lock with the lock nut. Repeat for the remaining stop bolt.

5. DOCUMENTATION

Spare parts list for range of worm gear actuators: IWSPARES. Torque tightening figures. Document No QC 40-2 Procedure for replacing old style output sleeves IW-OS1 Gearbox Installation Manual RG-INSTALL

41

Rotork GearsRegina HouseRing RoadBramleyLeedsEngland LS13 4ET C.F. 27.07.10 ISSUE 3

Ref: F:\Exeeco\GBOX\ENGINEER\ATEX\Instructions\Worm\IWSPARES.dft

SPARE PARTS LIST FOR IW RANGE OF WORM GEAR ACTUATORS

PART SECTION

SECTION

TYPICAL WORM EXPLODED VIEW

15

2716

11

1928

13

14

26

58

74

2 1

3

ITEM DESCRIPTION QTY SPARES1 GEARCASE2 BASEPLATE 13 WORM QUADRANT 14 WORMSHAFT 15 OUTPUT SLEEVE 1 (IW3 -11 ONLY)6 ENDCAP 17 INPUT FLANGE 18 INDICATOR PLATE 19 ANGULAR CONTACT BALL BEARING 2 (IW3-8), 6 (IW9 -11), 4 (IW12-13) YES10 SHIM 1 (WHERE APPLICABLE) YES11 SOCKET HEAD CAP SCREW/ DURLOCK 4 (IW3, IW12-13), 8 (IW4 -11)12 O-RING 1 YES13 O-RING 1 YES14 O-RING 1 YES15 STOP BOLT 2 (IW & MOW ONLY)16 HEX NUT 2 (IW & MOW ONLY)17 SCREWED FASTENER *² 4 (IW3 - 8), 8 (IW9 - IW13)18 SCREWED FASTENER *² 4 (IW3 -8), 8 (IW9 - IW13)19 NORDLOCK WASHER 4(IW3), 8( IW4 TO 11)20 KEY 1 (IW3 - IW11), 2 (IW12-13)21 NAMEPLATE 122 RIVET 4 X 3/16" 2 FOR METAL NAMEPLATE ONLY23 LABEL - SHCS/NORDLOCK WASHER 124* GREASE TO FILL GEARBOX25 O-RING OR SEALANT 2 YES26 O-RING OR SEALANT 1 YES27 SCREWED FASTENER *² 4 (IW3), 8 (IW4-10), 16 (IW11-13)28 O RING 4 (IW3), 8 (IW4 - IW11) YES

17

20

12

18 925 9

6

10

22

21

23

22

21

11

828

204

1

14

518

2510

9

925

7 12

17

19

23

15

16

313

262

27

6

FITTED TOUNDERSIDE OF

INDICATOR PLATE

*² : NOTE THAT NORDLOCK FASTENERS ARE OCCASIONALLY USED WITH THESE FASTENERS

SPARES ARE RECOMMENDED FOR 5 YEARS OPERATION

SPECIAL SOLID WORM WHEELS DO NOT HAVE OUTPUT SLEEVES & SCREWS, BUT DO HAVETHE SAME GEARBOX RATING

42

DeZURIK VENDOR INSTRUCTIONS ROTORK IQ RANGE ACTUATORS

Instruction DP00091June 2011

43

44

Larkey_M

Text Box

This page intentionally blank.

IQ RangeInstallation andMaintenance Instructions

This manual contains important safety information. Please ensure it is thoroughly read and understood before installing, operating or maintaining the equipment.

Publication number E170-3EDate of issue 04/09

Including Addendeum 03-10

2

Addendum to:E170-3E IQ Range Installation and Maintenance InstructionsDate of issue 04/09

page 14 Addition to Section 6.3

page 80 Replacement Approvals and additional

Flamepath Information

Addendum to E170-3E (date of issue 04/09)Addendum date of issue 03/10

45

3

6.3 Cable Entry

The cable entries on the actuator terminal housing are tapped either 1” NPT or 1½” NPT

page 14 page 80

European – Hazardous areaATEX (94/9/EC) II 2 GD cEx d IIB T4 Gb, Ex tb IIIC T120°C Db IP68Temperature -20 to +70°C (-4 to +158°F)*Option -30 to +70°C (-22 to +158°F)*Option -40 to +70°C (-40 to +158°F)*Option -50 to +40°C (-58 to +104°F)

Ex d IIC T4 Gb, Ex tb IIIC T120°C Db IP68Temperature -20 to +70°C (-4 to +158°F)*Option -30 to +70°C (-22 to +158°F)*Option -40 to +70°C (-40 to +158°F)*Option -50 to +40°C (-58 to +104°F)

Ex de IIB T4 Gb, Ex tb IIIC T120°C Db IP68Temperature -20 to +70°C (-4 to +158°F)*Option -30 to +70°C (-22 to +158°F)*Option -40 to +70°C (-40 to +158°F)*Option -50 to +40°C (-58 to +104°F)

Ex de IIC T4 Gb, Ex tb IIIC T120°C Db IP68Temperature -20 to +70°C (-4 to +158°F)*Option -30 to +70°C (-22 to +158°F)*Option -40 to +70°C (-40 to +158°F)*Option -50 to +40°C (-58 to +104°F)

Conditions of Safe Use

IQ Approvals12

Refer to actuator nameplate for unit specific approval details

4

IQ MAXIMUM FLAMEPATH GAPS

Flamepath Max. Gap (mm) Min Length (mm) Actuator Type and Size

46

5

Published and produced in the U.K. by Rotork Controls Ltd.

As part of a process of on-going product

to amend and change specifications

www.rotork.com

UKRotork plctel +44 (0)1225 733200fax +44 (0)1225 333467email [email protected]

USARotork Controls Inc.tel +1 (585) 247 2304fax +1 (585) 247 2308email [email protected]

The Rotork Setting Tool allows actuator control, indication and protection functions to be configured to suit site requirements. In addition, the new Setting Tool Pro also allows downloading of datalogger and uploading/downloading of configuration files. Files are transferred to and from the Setting Tool Pro via Rotork Insight.

It is essential that all the actuator settings are checked for compatibility with the valve, process and control system requirements before the actuator is put into service. Please read this publication.

When Rotork personnel or nominated agents are contracted to carry out site commissioning and/or acceptance, documentation of commissioned actuator configuration can be made available for customer records.

Rotork Setting Tool Pro

Rotork Setting Tool

I

47

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 Basic Settings for correct valve operation.

* Commissioning and adjustment of the Configuration Settings to suit site-specific control and indication requirements.

* Maintenance – Troubleshooting.

* Sales and Service.

Refer to Publication E180E2 for repair, overhaul andspare part instructions.

THE ROTORK IQ RANGE – THE FIRST VALVE ACTUATOR THAT YOU CAN COMMISSION AND INTERROGATE WITHOUT REMOVING ELECTRICAL COVERS.

Using the supplied infra-red Setting Tool to access the actuator set upprocedures, non-intrusive setting of torque levels, position limits and all other 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 is in the form of display text and help screens.

Setup, Alarm and Status text is available in English (default), Spanish, French and German.

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 PDA allows the Datalogger to be interrogated, as well as the complete actuator set up to be configured and recorded.

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, IQ Insight and other Rotork actuator ranges.

II

Identifying Actuator Parts

Motor Base Terminal Cover

Hand wheel

Oil plug

Control Cover

Conduit entries

Open / Close selector

Local / Remote / Stop selector

Oil plug

Hand / Autolever

Display windowName plate

Battery sealing plugMetal (8mm Allen key required)Plastic (10mm Allen key required)as appropriate.

Grease nipple (if fitted)

Oil plug

Side hand wheel

III

48

1

1 Health and Safety 2

2 Storage 3

3 Operating your IQ Actuator 3 3.1 Operating by Hand 3 3.2 Operating Electrically 3 3.3 Display – Local Indication 4 3.4 Display Status Indication – Travel 5 3.5 Display Status Indication – Control 5 3.6 Display Alarm Indication 5

4 Preparing Drive Bush 7 4.1 IQ10 to IQ35 7 Thrust Base Types A and Z 4.2 IQ10 to IQ35 8 Non-Thrust Base Type B 4.3 IQ40 to IQ95 8 Thrust Base Types A and Z 4.4 IQ40 to IQ95 9 Non-Thrust Base Type B

5 Mounting the Actuator 10 5.1 Rising Stem Valves – Top Mounting 11 5.2 Valve with Gearbox – Side Mounting 12 5.3 Non-Rising Stem Valves – Top Mounting 12 5.4 Handwheel Sealing 12

5.5 IQM Modulating Actuators 12 5.6 IQML Linear Drive Unit 12 5.7 IQML Adjusting Linear Stroke 13

6 Cable Connections 14 6.1 Earth/Ground Connections 14 6.2 Removing Terminal Cover 14 6.3 Cable Entry 14 6.4 Connecting to Terminals 15 6.5 Replacing Terminal Cover 15

7 Commissioning 16 7.1 The Setting Procedure 16 7.2 The Rotork Setting Tools 17 7.3 Entering the Actuator 20 Setting Procedure 7.4 Setting Mode – Password 20 7.5 New Password 20 7.6 Checking Mode 20 7.7 Crossroad 21 7.8 The Actuator Display – 21 Setting/Checking Mode 7.9 Returning to Valve Position Display 21

8 Commissioning – Basic Settings 22 Basic Settings Contents 23

9 Commissioning – Configuration Settings 31 Configuration Settings Contents 33 Default Options 63

10 Maintenance, Monitoring and Troubleshooting 65 10.1 Setting Tool Pro Download & Upload 68 10.2 Help Screens 71 10.3 IQ Infrared Diagnostic & Configuration 76 10.4 Environmental 77

11 Weights and Measures 78 Binary, Hexadecimal and Decimal Conversion Table 79

12 IQ Approvals 80 Approved Fuses 81

Appendix A 82

CONTENTS

Page

Page

Page

2

This manual is produced to enable a

Work undertaken must be carried out in

further information and guidance relating

and use of these actuators should be

applicable edition of the “IEE Wiring

The mechanical installation should be carried out as outlined in this manual

standards such as British Standard Codes

indicating that it is suitable for installation

temperatures has been indicated on the

and the use of the actuator should be

No inspection or repair should be undertaken unless it conforms to the

be carried out on the actuator as this

WARNING: Motor TemperatureUnder normal operation the temperature

WARNING: Thermostat Bypass

WARNING: Control and Indication

control and indication supplies higher

installation altitude must be restricted

WARNING: Enclosure Materials

fasteners and the thrust bases are

stainless steel fasteners and the thrust

The user must ensure that the operating

surrounding the actuator cannot lead

Where appropriate the user must ensure

WARNING: Operating by Hand

This actuator must only be located in areas where the risk of impact to the viewing window is low.

WARNING:

be dependent on remote control signal

Health and Safety1

49

3

If the actuator has to be installed but cannot be cabled it is recommended

The Rotork double-sealed construction

deterioration caused on-site once the

3.1 Operating by Hand

WARNINGWith respect to handwheel operation of Rotork electric actuators, under no circumstances should any additional lever device such as a wheel-key or wrench be applied to the handwheel in order to develop more force when closing or opening the valve as this may cause damage to the valve and/or actuator or may cause the valve to become stuck in the seated/backseated position.

Keep clear of the handwheel when engaging hand operation. Actuators driving valves via extension shafts may be subject to retained shaft torsion which can cause the handwheel to rotate when hand operation is engaged.

engaged until the actuator is operated

be locked in either position using a

3.2 Operating Electrically

Do not operate the actuator electrically without first checking, using the infra-red Setting Tool, that at least the Basic Settings have been made (refer to Section 8 page 22

Selecting Local/Stop/Remote OperationThe red selector enables either Local or

When the selector is locked in the Local

Fig. 3.1

Local Control With the red selector positioned at Local

Remote Control Rotate the red selector to the Remote

3 Storage2 Operating yourIQ Actuator

4

3.3 Display–Local Indication

Fig. 3.2 The Actuator Display

1.

2.

3.

4.

5.

6.

7. IR Icon - This icon flashes during infra

8.

modes of position indication:

amber light and one of the indicator

(See Figs 3.3, 3.4 and 3.5)

Open

Fig. 3.3

Mid Travel

Fig. 3.4

Closed

Fig. 3.5

LED Indicators

WARNING: Mid Travel LED colour may be affected by viewing angle and lighting level.

Open Limit

Closed Limit

Stopped

50

5

3.4 Display Status Indication – Travel

Closed Limit

Fig. 3.6

Closed Limit Actuator has reached the

Open Limit Actuator has reached the

Moving Open

Moving Closed

Stopped Actuator has stopped in a

Timer Active Interrupter Timer option

Refer to 9.13 page 59.

3.5 Display Status Indication – Control

seconds after the control mode or

Remote Control

Fig. 3.7

Local Control Local control selected -

Local Stop

Remote Control Remote control

Local Close Local close signal applied

Local Open Local open signal applied

Remote Close Remote close

Remote Open Remote open

Remote ESD

Remote Bus Open Remote Bus * open

Remote Bus Close Remote Bus* close

Remote Bus ESD Remote Bus*

* Bus Control option fitted may be Pakscan, Profibus, Modbus, DeviceNet or Foundation Fieldbus. Refer to actuator wiring diagram.

3.6 Display Alarm Indication

There are 2 alarm icons:

General Alarm:

Battery Alarm:

General Alarm

TORQUE TRIP CL

Fig. 3.8

Closed Limit

Closed LimitRemote Control

StoppedTORQUE TRIP CL

6

Valve Alarms

TORQUE TRIP CL

TORQUE TRIP OP

MOTOR STALLED

Control Alarms

ESD ACTIVE

Refer to 9.3

ESD Action page 36

INTERLOCK ACTIVE interlocks are configured on and are

Refer to 9.3 Interlockpage 38 Operation in the direction of an

Actuator Alarms

THERMOSTAT TRIP Motor thermostat has tripped due to the motor

until the thermostat resets

PHASE LOST

24V LOST

LOCAL CONTROL FAIL Check operation

CONFIG ERROR in the configuration (set up) of the

setting and check configuration

POS SENSOR FAIL

TORQ SENSOR FAIL

EEPROM MISSING Contact Rotork

Battery Alarm

Fig. 3.7

BATTERY LOW

BATTERY FLAT

When a low or flat battery alarm is displayed the battery should be replaced immediately. It is essential that the correct battery type is fitted to maintain actuator certification. Refer to page 65

After replacing a battery the alarm icon will continue to be displayed until the next check and may take up to 1 hour. Cycling the power will force a battery check and clear the alarm.

PWR LOSS INHIBIT

loss inhibit feature [OS] is enabled (refer to page 61

PWR LOSS INHIBIT and BATTERY FLAT

Open Limit BATTERY LOW

51

7

4.1 IQ10 to IQ35 Thrust Base Types A and Z

Removal of Drive Bush for Machining

Fig. 4 Bronze Drive Bush Fitted into Thrust Taking Base

sealed thrust bearing located on the

Fig. 4.1 Components of Type A Thrust Base

male thread (stop ring) is not

Re-assembly

Fig. 4.2

Preparing Drive Bush4

Socket set Allen key Torque Torque screw size bit size Nm lbs/ft

8

4.2 IQ10 to IQ35 Non-Thrust Base Type B

Types B3 and B4 removal:

Fig. 4.3

Fig. 4.4

Type B1

spring clip operates in the same manner

4.3 IQ40 to IQ95 Thrust Base Types A and ZRemoval of Drive Bush for Machining

Fig. 4.5 Locating Set Screw

Fig. 4.6 Removal of Retainer

Fig. 4.7 Type A Drive Bush

Fig. 4.8 Type A Drive Bush in Position 1

52

9

Fig. 4.9 Type A Drive Bush in Position 2

Fig. 4.10 Type Z3 Drive Bush

Fig. 4.11 Type Z3 Drive Bush in Position 3

Re-Assembly

that the actuator output shaft dogs

hole in the side of base and tighten to

4.4 IQ40 to IQ95 Non-Thrust Base Type B

Type B1

Fig. 4.12 Tightening Retainer Set Screw

Types B3 and B4

B3 is supplied pre-machined to ISO

B4 is supplied blank and must be machined to suit the input shaft of the

Fig. 4.13 B3/B4 Drive Bush

Fig. 4.14 B3/B4 Drive Bush in Situ

10

Refer to Weights and Measures page 78 for actuator weight.

WARNING: The actuator should be fully supported until full valve shaft engagement is achieved and the actuator is secured to the valve flange.

A suitable mounting flange conforming to ISO 5210 or USA Standard MSS SP101

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

Fig. 5

Fig. 5.1

Mounting the Actuator5

53

11

5.1 Rising Stem Valves – Top Mounting

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

Fig. 5.2

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

the opening direction to engage the

securing bolts but do not tighten at

thrust base and rotate the complete

actuator output shaft engage into the

Fig. 5.3

see table A

see table B

Table A Table B

Torque ( +10%) Size Nm lbs/ft

Torque Imperial Size Nm lbs/ft

Torque Metric Size Nm lbs/ft

–

12

5.2 Valve with Gearbox – Side MountingCheck that the mounting flange is at

5.3 Non-Rising Stem Valves – Top Mounting

5.4 Handwheel SealingEnsure that sealing plug in centre of

ensuring that moisture does not

5.5 IQM Modulating Actuators

the actuator terminal block as indicated

increase and therefore the number of actuator starts should be reduced

(refer to publication E110E for more information)

(refer to Sections 7, 8 and 9 commencing on page 16)

5.6 IQML Linear Drive Unit

arrangement attached to the base

(3 8 in) minimum and 120mm (434 in)

This adaptor consists of four pillars and

Fig. 5.4 IQML with Yoke

Fig. 5.5 IQML without Yoke

54

13

5.7 IQML Adjusting Linear Stroke

Fig. 5.6 Down Stop two Spanners

into the actuator until it comes to a

A grease nipple is situated in the base of the actuator to enable lubrication of

14

WARNING:

Ensure all power supplies are isolated before removing actuator covers.

breaker shall be mounted as close to the actuator as possible and shall be marked to indicate that it is the

WARNING:

Actuators for use on phase to phase voltages greater than 600V a.c. must not be used on supply systems such as floating, or earth-phase systems, where phase to earth voltages in excess of 600V a.c. could exist.

6.1 Earth/Ground Connections

6.2 Removing Terminal Cover

Fig. 6

Actuators containing a Setting Tool or Setting Tool Pro fitted to the inside of

label on the outside of the terminal

is particular to each actuator and must

A plastic bag in the terminal compartment contains:

Fig. 6.1 - Actuator containing Rotork Setting Tool.

Fig. 6.2 - Actuator containing Rotork Setting Tool Pro.

Fig. 6.3

6.3 Cable Entry

Cable Connections6

55

15

cable entries appropriate to the cable

6.4 Connecting to Terminals

On EExde enclosure units connections to the power and control terminals must be made using AMP type 160292 ring tabs for power and earth terminals and AMP type 34148 ring tabs for the control terminals.

is the same as that marked on the

When all connections are made ensure

6.5 Replacing Terminal Cover Heading

ATTENTION: RED PLASTIC PLUGS IN CONDUIT ENTRIES ARE FOR TRANSIT ONLY.FOR LONG TERM PROTECTION FIT SUITABLE METAL PLUGS.

ATTENZIONE: I TAPPI IN PLASTICA ROSSA PER L'ENTRATA CAVI SONO SOLOTEMPORANEI. PER UNA PROTEZIONE PERMANENTE PREGO SOSTITUIRLI CON

APPOSITI TAPPI METALLICI.

ATENCION: LOS TAPONES ROJOS DE PLASTICO EN LAS ENTRADAS DE CABLESON UNICAMENTE PARA TRANSPORTE. PARA PROTECCION PERMANENTE

COLOCAR TAPONES METALICOS APROPIADOS.

ACHTUNG: DIE ROTEN PLASTIKSTOPFEN SIND NUR FÜR DEN TRANSPORT GEEIGNET. FÜR DAVERHAFTEN SCHUTZ SIND DIESE GEGEN GEEIGNETE

BLINDSTOPFEN AUSZÜTAUSCHEN.

ATTENTION: LES BOUCHONS PLASTIQUES ASSURENT UNE PROTECTIONTEMPORAIRE. POUR UNE PROTECTION DEFINITIVE UTILISER DES BOUCHONS

METALLIQUES.

16

7.1 The Setting Procedure

first that enables commissioning to be

All the commissioning functions are

1. Basic Settings

2. Configuration Settings

indication and optional

All IQ actuator functions are configured before dispatch to Rotork standard default settings unless alternatives have been specified with the order. Should difficulty be encountered during commissioning the default settings can be reinstated, returning the actuator configuration to its original manufactured state. Site commissioning can then begin again (refer to Section 9.18 page 63)

The default function should be used

Actuator Display

Commissioning7

Position Display 50

m Torque and Position 50

m Password P? k PC k Ir k tP

m Crossroad cr k m

Basic Settings Configuration Settings

Limit Actions Control Mode

Note: The Basic Settings must be commissioned first.

56

17

7.2 The Setting Tool (old version)

SpecificationEnclosure IP67

Name Instructionm

k

-

+

indication mode

Infra-red local operation

Fig. 7.1 The Setting Tool

Setting Tool Battery Replacement

Battery replacement must be carried out in a safe area. To replace the battery 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 or Rayovac Alkaline Maximum NoAL-9V battery types. Refit cover ensuring red indicator LED faces the transmitter window in the back cover.

8 24

6

75

31

18

Commissioning continued7

7.2 The Setting Tool Pro (new version)

SpecificationEnclosure IP54

This Setting Tool Pro

Temperature Tamb = -30ºC to 50ºC

Name Instructionm

i

k

o

-

+

m

position indication mode

Infra-red local operation

Fig. 7.2 The Setting Tool Pro

8

2

7

6

11

5

3

1

4

10

12

57

19

Download / Upload Function

Pro

Setting Tool Pro Battery Replacement

Pro

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

In order to maintain hazardous area certification the actuator Setting Tool Pro shall only be fitted with the following AA size, alkaline-manganese, approved battery types:

Duracell, Coppertop, type MN1500 Duracell, Procell, type MN1500 GP, Super Alkaline, type GP15A

Other types of AA size batteries, including Duracell, Ultra, type MN1500, must not be fitted. For battery replacement see Section 7.

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

The enclosure of the actuator Setting Tool Pro is manufactured from the materials:

Polycarbonate, ABS blend Polycarbonate Silicon Rubber

If the actuator Setting Tool Pro is likely to come into contact with aggressive substances (e.g. solvents that may affect polymetric materials), then it is the responsibility of the user to take suitable precautions (e.g. regular checks as part of the routine inspections or establishing that the materials are resistant to the specific chemical) that prevent it from being adversely affected, thus ensuring that the type of protection is not too compromised.

No form of repair must be attempted on the actuator Setting Tool Pro.

When a button is depressed the Setting Tool Pro

and at a distance no greater than

Display Set-Up ModeThe Setting Tool and Setting Tool Pro

Close Action [C2] and Open Torque [tO]

This instruction manual uses both code

Close ActionClose on Torque

Open Torque40%

FunctionCode

Function

SettingCode

SettingOption

FunctionCode

Function

SettingValue

SettingValue

20

7.3 Entering the Actuator Setting Procedure

PRESS THE m KEY.

(For instantaneous torque & position monitoring, refer to Section 10, page 66.)

PRESS THE m KEY.

The Actuator Function Settingscan be protected by the Use

of a Password

7.4 Setting Mode – Password

[ld]

Use the + or -

PRESS THE KEY

Default Password,Setting Mode Enabled

7.5 New Password [PC]

PRESS THE k KEY.

[PC]+ or -

PRESS THE KEY.

Password Changed to [IE]

NOTE:

7.6 Checking ModeThe actuator function settings can be

Password Display, Checking Mode

Once the procedure has been completed

PRESS THE m KEY.

The procedure branch [Cr] (crossroad) (refer to Section

7.7 page 21).

Commissioning continued7

Enter PasswordID Hex

Password CorrectEnter Password

Change PasswordIE Hex

Enter PasswordID Hex

58

21

7.7 Crossroad [Cr]

To access the Basic Settings press the arrow m key (refer to Section 8 Commissioning Basic Settings page 22)

To access the Configuration Settings press the arrow k key (refer to Section 9 Commissioning Configuration Settings page 31).

7.8 The Actuator Display – Setting/Checking ModeActuator functions as laid out in the Basic and Configuration commissioning

The m

The k

code form in the top left portion of the

In setting mode the Setting Tool + or -

setting can be entered into the actuator pressing the key

Stored

TOP LEFT PORTION

TOP RIGHT PORTIONFunction Setting

LOWER DISPLAY

Typical Actuator Function DisplaySetting Mode Enabled

7.9 Returning to Valve Position Display

last Setting Tool operation the

m and k

m

Pro i

Basic SetupConfig Setup

Close Torque40%

22

Fig. 8

ELECTRICAL OPERATION MUST NOT TAKE PLACE UNTIL THE BASIC SETTINGS HAVE BEEN MADE AND CHECKED.

The actuator’s Basic Settings affect

This instruction assumes setting mode has been entered (refer to section 7.4 page 20)

Viewing the Basic SettingsWith the actuator mounted on the

Setting Tool at the actuator indicator

m k

(refer to page 23)

Power Off Setting

(refer to page 3)

infra-red Setting Tool communication

Settings and operation must be verified by electric operation and function test of the actuator to ensure correct operation.

8 Commissioning –Basic Functions

59

23

Viewing the Basic Settings

Function Description

Position Display 50 (This may be an open or closed symbol or a % open value.) m m 50 Torque and Position Display

m mP? k PC k Ir k tP Password k Password Change k IrDA k Torque Reference Profile

m mCr k Configuration Crossroad k Configuration Settings, refer to page 32.

C1 k C2 k C3 Direction to Close k Close Action k Open Action

m mtC k tO Torque Value Closing k Torque Value Opening

m mLC k LO Limit Closed k Limit Open

m m 50 Position Display

Fig. 8.1 Basic Setting Displays

BASIC SETTINGS CONTENTS page

C1 Direction to Close 24C2 Close Action 25C3 Open Action 26tC Torque Value Closing 27tO Torque Value Opening 28LC Set Limit Closed 29LO Set Limit Open 29

REFER TO SECTION 7, COMMISSIONING

24

The actuator can be configured to be

50

m 50

mP? k PC k Ir k tP mcr m c1 k c2 k c3 mtC k tO mLC k LO m 50

Using the + or -character conforming to correct closing

[C] in the Setting Field Indicating Clockwise to Close

[A] in the Setting Field Indicating Anti-clockwise to Close

corresponds to the established closing direction

PRESS THE KEY.

PRESS THE k KEY.

Direction to CloseC1

Close DirectionClockwise

Close DirectionAnticlockwise

60

25

The actuator can be configured to close

50

m50

mP? k PC k Ir k tP mcr m c1 k c2 k c3 mtC k tO mLC k LO m50

Refer to valve manufacturer for recommended setting.

Valve type Close Open

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

Using the + or -

[CL] in the Setting Field Indicating Close on Limit - default setting.

[Ct] in the Setting Field Indicating Close on Torque.

PRESS THE KEY

PRESS THE k KEY.

NOTE:

[tC] in seating the (refer to [tC] page 27)

Close ActionC2

Close ActionClose on Torque

Close ActionClose on Limit

26

The actuator can be configured to

Refer to valve manufacturer for recommended setting. In the absence of valvemaker instructions set “Open Limit”

50

m50

m P? k PC k Ir k tP m cr m c1 k c2 k c3 m tC k tO m LC k LO m50

Using the + or -

[OL] in the Setting Field Indicates Open on Limit - defualt setting.

[Ot] in the Setting Field Indicates Open on Torque.

PRESS THE KEY.

(stored)

PRESS THE k KEY.

NOTE:

[tO] in back seating (refer to [tO] page 28)

Open ActionC3

Open ActionOpen on Torque

Open ActionOpen on Limit

61

27

Refer to valve manufacturer for recommended value.

50

m50

mP? k PC k Ir k tP m cr m c1 k c2 k c3 m tC k tO mLC k LO m50

Using the + and -

If the actuator fails to complete a closed valve operation due to the set torque being reached (Torque Trip CL this may indicate a valve and/or process problem or change. It is the responsibility of the user to ensure the valve and process conditions are within specified operational limits before increasing the Set Close torque value.

PRESS THE KEY.

(stored)

PRESS THE k KEY.

NOTE:

40% of Rated Torque

99% of Rated Torque

Rated Torque

Close TorquetC

Close Torque40%

Close Torque99%

Close Torque100%

28

Refer to valve manufacturer for recommended value.

50

m50

m P? k PC k Ir k tP m cr m c1 k c2 k c3 m tC k tO mLC k LO m50

BOOST SHOULD NOT BE SELECTED WHEN THE ACTUATOR HAS BEEN CONFIGURED TO OPEN ON TORQUE (refer to [C3] page 26) UNLESS BACK SEATING AT RATED TORQUE IS ACCEPTABLE.

Using the + and -

In the absence of a recommended

If the actuator fails to complete a open valve operation due to the set torque being reached (Torque Trip OP 5) this may indicate a valve and/or process problem or change. It is the responsibility of the user to ensure the valve and process conditions are within specified operational limits before increasing the Set Open torque value.

NOTE:

PRESS THE KEY.

(stored)

PRESS THE m KEY.

40%

99%

Rated

Boost

m

Open TorquetO

Open Torque40%

Open Torque99%

Open Torque100%

Open TorqueBoost

62

29

NOTE: It is possible to set the Open Limit Position [LO]

50

m50

mP? k PC k Ir k tP mcr m c1 k c2 k c3 m tC k tO m LC k LO m50

NOTE: When in checking mode Set Limit Closed [LC]

With [LC] displayed

Limit Closed

Move valve manually to the closed position. Allow for overrun by winding actuator output open by 1/2 to 1 turn.

PRESS THE KEY.

and the

indicating closed limit position has been

PRESS THE k KEY.

To check closed limit position hand

50

m 50

m P? k PC k Ir k tP m cr m c1 k c2 k c3 m tC k tO m LC k LO m 50

NOTE: When in checking mode Set Limit Open [LO]

With [LO] displayed

Limit Open

Move valve manually to the open position. Allow for overrun by winding actuator output closed by 1/2 to 1 turn.

PRESS THE KEY.

indicating open limit position has been

PRESS THE m KEY.

(refer to Fig. 3.3. page 4)

Set Limit ClosedLC Set Limit OpenLO

Set Close LimitMove to Close

Set Open LimitMove to Open

30

50

m 50

m P? k PC k Ir k tP m cr m c1 k c2 k c3 m tC k tO m LC k LO m 50

indicate that the actuator is in the open

With the correct settings made electric

Return toPositional Display

63

31

Fig. 9

The Configuration Settings can be configured to suit site control and

that Basic Settings such as limits and

the Configuration Settings (refer to page 22)

information about the site or process

terminal connection detail and standard

Power Off Setting

(refer to page 3)

Settings and operation must be verified by electric operation and function test of the actuator to ensure correct operation.

9 Commissioning –Configuration Settings

32

Positional Display

m

m P? k PC k Ir k tP

m Contact Function Value Contact Form

cr k Contact S1 r1 k r1 k r1 m Contact S2 r2 k r2 k r2 m Contact S3 r3 k r3 k r3 m Contact S4 r4 k r4 k r4 m Control Mode Configuration A1 k A2 k A3 k A4 k A5 k A6 k A7 k A8 k A9 k At

m Contacts CPT Control Source

Option Selection OE k OI k Od k OJ k Or k OS k OH k OU k UL

m Option Functions – If Analogue, Bus System or Interrupter Timer control options are fitted their appropriate set-up screens will be automatically inserted here.

m

Service Mode Un k UI k U2 k Ur k UP

m Help Screens H1 k H2 k H3 k H4 k H5 k H6 k H7 k H8 k H9

m Default Option d1 k d2

m Fig. 9.1 Configuration Settings

IrDAcomms

PrimaryFunctions

m

50

Torque ReferenceProfile

64

33

configured to suit site control and

k and m

Options Setting Tool Local Control [Or] [OS] are

m [Cr]

Configuration Settings in the checking

Configuration Settings in the setting

(refer to Section 7)

Fig. 9.2 Fig. 9.3

PRESS THE k KEY

9.1

CONFIGURATION SETTINGS

page

9.1 Accessing the Configuration Settings 339.2 Indication Contacts S1, S2, S3 and S4 349.3 Control Mode Configuration 369.4 Option Extra Indication Contacts S5–S8 399.5 Option CPT (4-20mA Indication) 409.6 Option Folomatic (Analogue Position Control) 419.7 Remote Control Source 449.8 Bus System Option Pakscan 459.9 Bus System Option Modbus 489.10 Bus System Option Profibus DP 519.11 Bus System Option DeviceNet 549.12 Bus System Positioning Control Settings 579.13 Option Interrupter Timer 599.14 Setting Tool Local Control 619.15 Inhibit Operation After Power Loss 619.16 Indicator LEDs 629.17 Display Language 629.18 Default Options 6410.2 Help Screens 7110.3 IrDA Diagnostics and Configuration 76

Accessing theConfiguration Settings

Basic Setup Config Setup

Basic SetupConfig Setup

34

Code Function

[CL] Closed Limit [OP] Open Limit [Po] Position % Open [rr] Motor Running [dC] Closing [dO] Opening [d?] Moving [HA] Hand Operation [bL] Moving-Blinker [UA] Valve Alarm [tC] Torque Trip Close (direction) [tO] Torque Trip Open (direction) [tt] Torque Trip [tl] Torque Trip Mid [St] Motor Stalled [LS] Stop Selected [Lo] Local Selected [rE] Remote Selected [CA] Control Alarm [ES] ESD Active

[Ol] Open Interlock Active [Cl] Close Interlock [lL] Interlock Active [AA] Actuator Alarm [Ht] Thermostat Tripped [LP] Lost Phase * [24] 24V Power Failure ** [bA] Battery Low [rP] Relay Parity [PA] Partial Stroke Active [PE] Partial Stroke Error

open [no] [nc]

The procedures for setting up contacts

Unless specified with order, the default settings for indication contacts are as follows:

S1 – [CL] Closed Limit [no]

S2 – [OP] Open Limit [no]

S3 – [CL] Closed Limit [nc]

S4 – [OP] Open Limit [nc]

* [LP]

** [24]

Using the + or -

PRESS THE KEY.

Contact S1 Configured to Trip at Valve Closed Limit

PRESS THE k KEY.

Contact S1 - Functionr1 9.2 Indication ContactsS1, S2, S3 and S4

S1 FunctionClose Limit

65

35

function is set to [P0] Position Open

When the S contact function is set to [P0]

No other contact function requires a value to be set.

Using the + or -

PRESS THE KEY.

Value Set to Indicate25% Open

PRESS THE k KEY.

Use the + or -[nO] Normally Open and [nC] Normally Closed

PRESS THE KEY.

Contact S1 Configured as a Normally Open Contact

NOTE: If function [PO] Position Open is selected and it is configured as a

PRESS THE m KEY.

r1 Contact S1Contact Form

S1 ContactNormally Open

Contact S1 - Valuer1

S1 % Position25%

36

The Control Mode Configuration affects

There are 10 configurable control functions:

Code Function

[A1] ESD Action

[A2] ESD Contact Type [A3] ESD Override Stat [A4] ESD Override Interlocks [A5] ESD Override Local Stop [A6] Maintain Local Control [A7] 2-wire Remote Priority [A8] Interlocks [A9] Conditional Control [At] Torque Switch Bypass.

[SP] Stay Put

Press the + or -

[OF] Off

[CL] Close

[SP] Stay Put

[OP] Open

PRESS THE KEY.

[nO] Normally Open

[nO] Normally Open

[nC] Normally Closed the signal must

Press the + or -

PRESS THE KEY.

Actuator Responds to a Normally Open ESD Contact (Signal Applied)

Thermostat is [OF] NoThe thermostats remain in circuit and

Danger: Actuator hazardous area certification is invalidated while the thermostats are bypassed.

[A3]

[A3] = [OF] No

[A3] = [On] Yes

ESD ActionA1 ESD Contact TypeA2 A3Control ModeConfiguration

ESD Override Thermostat

ESD ActionClose

ESD Contact TypeNormally Open

ESD OverrideStat: No

9.3

66

37

Interlocks is [OF] No

+ or -[On] Yes

PRESS THE KEY.

Local Stop is [OF] No

+ or - [On] Yes

PRESS THE KEY.

The default setting for Local Actuator Pushbutton control is self-maintained [On] Yes

If non-maintained actuator pushbutton

+ or -[OF] No

PRESS THE KEY.

[SP] Stay Putclosed remote control signal are applied

Use the + or -

[OP] Open

[SP] Stay Put

[CL] Close

PRESS THE KEY.

2-wire Control – Stay Put Priority

ESD OverrideInterlocks: No

ESD OverrideLocal Stop: No

Maintain LocalControl: Yes

2-Wire RemotePriority: Stay

A4 ESD OverrideInterlocks A5 ESD Override

Local Stop A6 MaintainLocal Control A7 2-wire Remote

Priority

38

[OF] Disabled

publication E120E for interlock control

press the + or -

[On] Enabled

PRESS THE KEY.

Note: If interlocking is required in only one direction, it will be necessary to connect a link between the actuator terminals associated with the other direction. Refer to wiring diagram.

partial stroke test using a signal applied to the open interlock input to initiate

is [OF] Disabled

To enable partial stroke testing press the + or -

[PS] Partial Stroke

PRESS THE KEY.

To access partial stroke test settings PRESS THE m KEY.

conditional on both a control signal (open or close) and the appropriate interlock signal being applied

Interlocks [A8] must be set [On] Enabled

The default setting for conditional control is [OF] Disabledconditional control press the + or -

[On] Enabled

PRESS THE KEY.

[OF] Off

+ or -

[On]

PRESS THE KEY.

[tC] Close Torque [tO] Open Torque

Interlocks Partial StrokeA8 A8 Conditional ControlA9 Torque Switch BypassAt

InterlocksDisabled

InterlocksPartial Stroke

ConditionalControl: Disabled

Torque SwitchBypass: Off

67

39

[r5][r6] [r7] and S8 [r8]

Check actuator circuit diagram for

included the set-up procedure and

(refer to Section 9.2 page 34)

S5 [r5] Close limit

S6 [r6] Open limit

S7 [r7] Torque trip mid

S8 [r8] Remote selected

NOTE:

effect on the indication output of the

Contact Option makes an additional

Press the + or -Contact Option set-up screens [On]

PRESS THE KEY.

PRESS THE m KEY TO ACCESS S5 TO S8 SET-UP DISPLAYS.

The procedure for setting S5 to S8 is the same as that for S1 to S4 (refer to Section 9.2 page 34)

Extra ContactsMenu: On

Extra ContactsMenu: Off

9.4 Option ExtraIndication Contacts OE Display Extra Contact

Set-up Screens

40

Setting instructions for actuators including a CPT providing 4-20mA analogue position feedback.

With [HI]Close=4mA Open=20mA

If Close=20mA Open=4mAthe + or - [LO]

PRESS THE KEY.

NOTE: If the actuator has options

recommissioned (refer to Section 9.6 Folomatic [OI] page 41)

9.5 Option CPT [OI] –4-20mA Indicator

Analog FeedbackCL=4mA OP=20mA

68

41

Setting instructions for actuators including a Folomatic proportional controller for use in analogue valve position control.

The Folomatic is an optional control device. Check actuator wiring diagram for inclusion.

Before setting the parameters for Option Folomatic ensure Remote Control Source [Od] has been selected to [bo] in Section 9.7.

This instruction lists the Folomatic

assumes that all Folomatic functions are

The actuator should be selected in Local

connected to terminals 26(+ve) and 27(–ve) (refer to wiring diagram)

Before commissioning of the Folomatic

Feedback must be set to suit the

With [HI]

+ or - [LO] CL=20mA

PRESS THE KEY.

If setting [OI] is modified after

Press the m

Using the + or - [ l] Current for current input signal or [ U] Voltage

PRESS THE KEY.

range screen [Fr] Analog Signal

Press the k [Fr] Analog Signal

Analog FeedbackCL=4mA OP=20mA

9.6 Option Folomatic –Analogue Control Folomatic FeedbackOI FI Analogue

Signal Type

Analog SignalType: Current

42

Using the + or -

If [FI] is set to current[FI] is set to Voltage

.

0–20mA Range Selected

0-20V Range Selected

PRESS THE KEY.

The

Press the k [FL] Low Set Point Position

APPLY MINIMUMSET POINT SIGNAL

Using the + or -

[ ] [ ] Closed[00] to [99] = percentage open[ ] Open

LOW set point

PRESS THE KEY.

Press the k [FH] High Set Point Position

APPLY MAXIMUMSET POINT SIGNAL

Using the + or -


HIGH set point

PRESS THE KEY.

Press the k [Fd] Deadband

If the actuator hunts or responds

Use the + or -

PRESS THE KEY.

Press the k [Ft] Motion Inhibit Time

Deadband1.2%

Fd DeadbandAdjustment Fr Input

Signal Range FL Valve PositionLOW Set Point FH Valve Position

HIGH Set Point

Analog SignalRange: 4-20mA

Low Set PointPosition: Closed

High Set PointPosition: Open

Analog SignalRange: 0-20V

69

43

The motion inhibit timer introduces

Use + or -

it is recommended that motion inhibit time should not be set to less than 5 seconds (refer to note on page 61)

PRESS THE KEY.

Press the k [FA] Loss of Signal

Use + or - [On] or disable [OF] action on loss of set point

[On] Failsafe [FF]

[OF] Go to Low SP

PRESS THE KEY.

NOTE:

[FF] [FA] has been set to [On]

Press the k [FF] Failsafe Action

[FA] Loss of Signal set to [On] Failsafe

Use + or -input signal:

[Lo] Go to Low SP position

[SP] Stay Put

[Hl] Go to High SP

PRESS THE KEY.

feature disabled as the default in order

+ or - [On]

PRESS THE KEY.

Commissioning of the Folomatic is

Motion InhibitTime: 05 seconds

Loss of SignalFailsafe

Failsafe ActionGo to Low SP

Ft Motion InhibitTimer Adjustment FA Action On Loss of

Set Point Signal Failsafe ActionFF

Manual / AutoDisabled

FC Manual/AutoSelection

44

2 - Analogue control-Option Folomatic

Option Pakscan Option Modbus Option Profibus Option Foundation Fieldbus

The setting for Remote Control Source

The setting of Remote Control Source

[rE] Hard-Wired Only contact control

[oP] Network

[bo] Folomatic: Analogue Proportional control

[OF] Remote Disabled: Remote control disabled

To change the remote source press the + or -

PRESS THE KEY.

Standard HardwiredRemote Control

Remote Control Source9.7 Remote Control SourceOd

Control TypeHard-wired Only

70

45

Setting instructions for actuators including an optional Pakscan Field

Before setting the parameters for Option Pakscan ensure Remote Control Source [Od] has been selected to [oP] in Section 9.7. (refer to page 44)

The actuator Pakscan Field Control Unit

The actuator must be in “Loopback” and isolated from Pakscan loop traffic

Using the + or -

(refer to table on page 79)

PRESS THE KEY.

Press the k [Pb] Baud Rate

The actuator Pakscan Field Control Unit baud rate must be set to the loop baud

the selected baud rate must be common to the master station and all the field

The actuator must be in “Loopback” and isolated from Pakscan loop traffic

Using the + or -

[01] = 110 baud

[03] = 300 baud

[06] = 600 baud

[12] = 1200 baud

[24] = 2400 baud

PRESS THE KEY.

Press the k [PF] Aux I/P Mask

Node AddressHex 01 : Dec 001

9.8 Bus SystemOption Pakscan

PA Pb PakscanBaud Rate

Baud Rate2400 Baud

Pakscan NodeAddress

46

in addition to the standard control and feedback features incorporated into the

closed (refer to page 79 for Binary, Hexadecimal and Decimal Conversion Table)

Left side hex character Right side hex character Aux 4 to 1 (function) AUX 4 to 1 (Invert)Bits 4 3 2 1 4 3 2 1

When used for remote control of the actuator bits 4 to 1 of the function character

Rules

1. Function bit set to ‘‘0’’


3. ESD Control[A2] should be set to

[nO] [A1](refer to page 36)

4. Stop (Maintain) Control

PF Pakscan RemoteAuxiliary Input Mask

71

47

5. Remote I/P SettingEnsure that the correct [Od] Control Type

For Pakscan this is [oP] Network

[PF] Aux I/P Mask is [OF] 0000 1111

Examples

Aux I/P 4 3 2 1

Function 1 1 1 1 = F

Invert 0 0 1 1 = 3 i.e. set [PF] to [F3]

Aux I/P 4 3 2 1

Function 0 0 1 1 = 3

Invert 0 0 1 1 = 3 i.e. set [PF] to [33]

Aux I/P 4 3 2 1

Function 1 1 0 0 = C

Invert 1 0 0 0 = 8 i.e. set [PF] to [C8]

PF Pakscan RemoteAuxiliary Input (continued)

Using the + or -

Auxiliary Input Mask [OF]

PRESS THE KEY.

For Pakscan module positioning settings [OF]

If Pakscan positioning control is PRESS THE m KEY.

[FL] Low Set Point Position (refer to page 57)

PF Pakscan RemoteAuxiliary Input

Aux I/P MaskBits: 0000 1111

48

Setting instructions for actuators including an optional Modbus RTU

Before setting the parameters for Option Modbus ensure Remote Control Source [Od] has been selected to [oP] in Section 9.7. (refer to page 44).

The actuator power must be cycled for the changes to take effect.

The Modbus module must be allocated

To set the address the Modbus module

Using the + or -

PRESS THE KEY.


The Modbus module must be set to the

baudrate the Modbus module must be

Using the + or -

[01] = 110[03] = 300 [06] = 600[12] = 1200 [24] = 2400[48] = 4800 [96][19] [38] = 38400[57] = 57600 [11] = 115200

PRESS THE KEY.


9.9 Bus SystemOption Modbus [OP]

PA Modbus BaudratePb

Node AddressHex 01 : Dec 001 Baud Rate

2400 Baud

Modbus NodeAddress

72

49





Rules






PF Modbus RemoteAuxiliary Input

50

Using the + or -

PRESS THE KEY.

Press the k [PP] Modbus Parity

Using the + or -

[no] None

[En] Even

[Od] Odd

No Parity Bit

PRESS THE KEY.

For Modbus module positioning settings and action on loss of signal setting [OF] (refer to page 57)

If Modbus positioning control and action on loss of communication are

PRESS THE m KEY.

[FL] Low Set Point Position (refer to page 57)

PF Modbus RemoteAuxiliary Input (continued) Modbus ParityPP

5. Remote I/P SettingEnsure that the correct [Od] Control Type setting is selected (refer to page 44)

For Modbus this is [OP] Network


Examples

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

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

Aux I/P 4 3 2 1Function 1 1 0 0 = CInvert 1 0 0 0 = 8 i.e. set [PF] to [C8]


Modbus ParityNone

73

51

Setting instructions for actuators

Before setting the parameters for Option Profibus ensure Remote Control Source [Od] has been selected to [oP] in Section 9.7. (refer to page 44).

Any settings made locally at the actuator may be overwritten by the host on startup unless the GSD files are locked on the Profibus card. Refer to publication S420E available from www.rotork.com


To set the address the Profibus module

Using the + or -

(refer to page 79 for conversion)

PRESS THE KEY.


[Pb] has no relevance for the Rotork Profibus DP Mk.2 card.

k [PF] Aux I/P Mask

9.10 Bus SystemOption Profibus DP [OP]

PA


Profibus NodeAddress

52





Rules





4. Stop/Maintain Control

PF Profibus RemoteAuxiliary Input

74

53

5. Remote Source Setting [Od] Ensure that the correct [Od] Control Type setting is selected (refer to page 44)

For Profibus this is [OP] Network


Examples




PF Profibus RemoteAuxiliary Input (continued)

Using the + or -

PRESS THE KEY.

If Profibus positioning control and action on loss of communication are

PRESS THE m KEY.

[FL] Low Set Point Position

PF Profibus RemoteAuxiliary Input


54

Setting instructions for actuators

Before setting the parameters for Option DeviceNet ensure Remote Control Source [Od] has been selected to [oP] in section 9.7. (refer to page 44)


Using the + or -

PRESS THE KEY.


Using the + or -

[01] = 125 k baud

[03] = 250 k baud

[06] = 500 k baud

PRESS THE KEY.


Option DeviceNet9.11 PA DeviceNet BaudratePb


Baud Rate500k baud

DeviceNet NodeAddress

75

55



Rules






PF DeviceNet RemoteAuxiliary Input

56

PF DeviceNet RemoteAuxiliary Input (continued)

5. Remote I/P SettingEnsure that the correct [Od] Control Type setting is selected (refer to page 44)

[OP] Network


Examples




Using the + or -

PRESS THE KEY.

settings and action on loss of signal setting [OF] (refer to page 57)


76

57

Limited Range Positioning is a selectable

to those used for digital Closed and

positioning can be set using the [FL] Low Set Point Position and [FH] High Set Point Position

respond to a digital Open or Close host

Any settings made locally at the actuator may be overwritten by the host on startup unless the GSD files are locked on the Profibus card. Refer to publication S420E available from www.rotork.com

[FL] Low Set Point Position is the position

Note that the position set for [FL]

Use the + or -

0% DV = Valve Closed

PRESS THE KEY.

Press the k [FH] High Set Point Position

[FH] High Set Point Position is the

Note that the position set for [FH]

Use the + or -

100% DV = Valve Open

PRESS THE KEY.

Press the k [Fd] Deadband

Use the + or -

PRESS THE KEY.

Press the k [Ft] Motion Inhibit Time

9.12 Bus System PositioningControl Settings FL Bus System Valve

Position at 0% DV FH Bus System ValvePosition at 100% DV

Low Set PointPosition: Closed

High Set PointPosition: Open

Fd Bus SystemDeadband Adjustment

Deadband2.5%

58

reduce the number of starts per hour and to smooth out fluctuations if

Use the + or -

[00] to [99]

PRESS THE KEY.

Press the k [FA] Loss of Signal

can be set to respond on loss of host

for a loss of communications addressed

The default setting is off [OF] and the

Use the + or -

[On] Failsafe [FF]

[OF] Go to Low SP

Failsafe Action Enabled

PRESS THE KEY.

Press the k [FF] Failsafe Action

[FA]

Use the + or -

[Lo] Go to Low SP

[SP] Stay put

[HI] Go to High SP

PRESS THE KEY.Motion Inhibit

Time: 05 secondsLoss of Signal

Failsafe

Failsafe ActionGo to Low SP

Ft Bus SystemMotion Inhibit Time (MIT)

FA Modbus, Profibus & DeviceNetAction on Loss of Signal

FF Modbus, Profibus& DeviceNetFailsafe Action

77

59

Setting instructions for actuator including an interrupter timer.

The interrupter timer enables pulsed

as a response to local and remote

The interrupter timer is an optional

When fitted, the timer will be made available for operation.

The Interrupter cannot be enabled or disabled using the Setting Tool.

Interrupter Timer Interrupter TimerDisabled Enabled

additional series of settings can be m

NOTE: If the timer option is not m

Press the m

The default for timer direction is [CL]start in closing

and stop in opening

+ or -

[OP] Opening

PRESS THE KEY.

Pulsed Operation Around the Closed Position

NOTE: Instructions [JC] and [JO] are for timer operation around the Closed

[JC] and start for stop [JO]

Press the k [JC] Timer Start Position

Using the + or -for the TIMER TO START WHEN THE VALVE IS CLOSING.


Timer Set to Start Pulsing when Closing Valve Reaches 25% Open

PRESS THE KEY.

closing stroke select [JC] to [ ] [ ]

Press the k [JO] Timer Stop Position

9.13 OptionInterrupter Timer OJ Interrupter Timer

Enabled/Disabled Jd Interrupter TimerDirection

JC Position in ValveClosing Stroke forTimer to Start

Int. TimerDisabled

Int. TimerEnabled

Timer StartClosing

Timer StartPosition: 25%

60

Using the + or -for the TIMER TO STOP WHEN THE VALVE IS OPENING.

[ ] [ ] Closed[00] to [99] = percentage open

[ ] Open

Timer Set to Stop Pulsingwhen Opening ValveReaches 25% Open

PRESS THE KEY.

stroke select [JO] to [ ] [ ]

Press the k [Jn] Timer On Time

Using the + or -

Actuator Run PeriodSet for 5 Seconds

PRESS THE KEY.

Press the k [JF] Timer Off Time

Using the + or -

Actuator OFF PeriodSet for 25 Seconds

PRESS THE KEY.

Press the k [JE] Timer Override ESD (refer to note on Page 61)

Refer to [A1] [A3] (refer to page 36 for ESD settings)

timer is [OF] No

+ or - [On] Yes

ESD Override Timer OFF

PRESS THE KEY.

Timer StopPosition: 25%

Timer On Time05 Seconds

Timer Off Time25 Seconds

Timer OverrideESD: No

JO Position in Valve OpeningStroke for Timer to Stop Contactor On TimeJn Contactor Off TimeJF JE ESD Override

Interrupter Timer

78

61

1 6

With a Folomatic option fitted and

Folomatic Motion Inhibit Timer must

set for the Interrupter Timer “contactor

The default setting for Setting Tool Local Control is [OF] Control Disabled

To enable Setting Tool Control press the + or - [On]

PRESS THE KEY.

(refer to page 17)

Local Setting Tool Control Enabled

Vandal resistant actuators ONLY

[Or] Vandal Resist

[On] Local Only

[OF] Control Disabled

[rE] Remote Only

The default setting for this protection option is disabled [OF]. When disabled it is important that the actuator is not manually operated during a power failure if the battery is low as changes in position cannot be tracked - refer to page 6 for battery level status display. Should this occur the limits must be reset before electric operation takes place- refer to LC/LO page 27. Locking the hand auto lever can prevent manual operation

the + or - [On]

PRESS THE KEY.

Press the k [OH] Close Colour

Example

Note

9.14 Setting ToolLocal Control [Or] 9.15 Inhibit Operation

After Power Loss [OS]

I-R Tool ControlOn

Power LossInhibit : Off

62

Close LED ColourOH

The default close limit position indicator colour is [gr] Green

+ or -

[rE] Red

PRESS THE KEY.

indicating that it has been set

Press the k [OU] Mid-Travel LED

indicator colour is [OF] Off

press the + or -

[On] On

PRESS THE KEY.

Press the k [UL] Language

Press the + or -

Deutsch

French Français

Spanish Español

Close ColourGreen

Mid-Travel LEDOU

Mid-Travel LEDOff

Display Language9.17

LanguageEnglish

Indicator LEDs9.16

LanguageUL

79

63

d1 Rotork standard or customer specified Basic and Configuration Settings.

d2 Limit positions only – factory set limits.

NOTE:

If d1 is entered, all Basic and Configuration Settings except limit positions will return to their default setting. See the table opposite for Rotork standard settings. Basic settings (except limits) and Configuration Settings must then be checked and reset as required (refer to Basic Settings page 22 and Configuration Settings page 31)

If d2 is entered the limits will be reset, with the actuator positioned at 50%. Limits must then be reset to the suit the valve (refer to Basic Settings page 20)

Rotork standard [d1] Default settings for IQ:

Function [d1] Default Setting[P?]

[Ir] [On]

Basic Settings[C1] [C]

[C2] Close Action [Cl] Close on Limit

[C3] Open Action [Cl] Open on Limit

[tC] [40]

[tO] [40]

Configuration Settings[r1] Indication Contact S1 [CI]/[nO]

[r2] Indication Contact S2 [OP]/[nO]

[r3] Indication Contact S3 [CI]/[nC]

[r4] Indication Contact S4 [OP]/[nC]

[A1] [SP]

[A2] [nO]

[A3] [OF]

[A4] [OF]

[A5] [OF]

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

9.18 Default Options[d1] and [d2]

64

Rotork standard [d1] Default settings continued:

Function [d1] Default Setting

[A7] [SP]

[A8] Interlocks [OF]

[A9] Conditional Control [OF] Function disabled

[AE] [OF] Function disabled

[OE] [OF]

[OI] Option CPT [HI] 4mA at Closed

[Od] Remote Source [rE] Unless option fitted (refer to 9.7 page 44.)

[OJ] Option Interrupter Timer [OF]

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

[OS] [OF] Protection off

Option Extra Indication Contacts (when fitted) - refer to wiring diagram

[r5] Indication Contact S5 [CI]/[nO]

[r6] Indication Contact S6 [OP]/[nO]

[r7] Indication Contact S7 [tI]/[nO]

[r8] Indication Contact S8 [rE]/[nO]

The Rotork standard default settings are subject to change without notice.

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

To reinstate [d1] [d1]

PRESS THE KEY.

[d1]

[d2]

PRESS THE KEY.

[d2]

Limits must now be reset. Refer to page 29.

[d1] Displayed [d2] Displayed

9.18 Default Options[d1] and [d2] cont.

Restore Config Reset Limits toRange 25 Turns

80

6510 Maintenance, Monitoring

and Troubleshooting

Maintenance

complete protection for the actuator

maintenance or inspection is carried

Electrical supplies must be isolated

Routine maintenance should include

* Check the actuator enclosure for

build up of dust or contaminant

(refer to page 78 for lubricants).

The Actuator Battery

position updating circuits and the

the current position is updated and

WARNING:The battery holder in the actuator gearcase also protects the user from the hazardous live connections inside the actuator and therefore it must not be damaged. The actuator must be isolated or disconnected if the battery holder has to be removed from the actuator gearcase.

In normal circumstances battery replacement interval should not exceed 5 years. Ambient temperature and plant operating conditions may affect battery life.

(refer to page 5)

Battery Replacement

permit’’ or other local regulation before

reference being lost for the duration

recommended that the actuator limits

(refer to Section 8 Commissioning Basic Settings, page 22)

Battery RemovalThe actuator must be selected to Stop using the red selector (refer to page 3)

sealing plug situated on the main

66

Fig. 10.1

Battery Types

For FM and CSA certified enclosures use

Fitting Replacement BatteryFit the pull strap around the

ensuring ‘‘O’’ ring is in good condition

sealing plug to 8 Nm (6 lbsft) using the

Oil

ambient temperatures ranging from

oil changes (refer to Weights and Measures Section 11, page 78)

Torque and Position Monitoring

(refer to pages 27, 28)

PRESS THE m KEY.

representation in the form of a bar

range: [00] to [99]

[HI]

[ ] [ ][00] to [99] = percentage open[ ]

+ or -

10 Maintenance, Monitoringand Troubleshooting cont.

Torque = 19%

81

67

Torque – Reference Profile

used to plan and determine periodic

After commissioning has taken place and the process is running under

using Rotork Insight in order to determine changes in performance of

Storing a Reference Profile

[tP]

50

m50 Torque m P? k PC k Ir k tP m cr k Configuration Settings m Basic Settings

Once the reference stroke (close to

the m

the

Press the k[tP] screen:

Fig. 10.2

Pressing the measured “reference” close-open and

Press the k and m

10 Maintenance, Monitoringand Troubleshooting cont.

Torque ProfilePress To Set

68

Troubleshooting

first that can be commissioned and

fast and complete fault finding to be

Question: With power on, the actuator display is not backlit. Position indicator lamp not illuminated. What is wrong?Answer:

(refer to Section 3.3 page 4 – The Actuator Display)

Question: With power off, the actuator does not display position. What is wrong?

Answer:

(Refer to Section 3.3 page 4 – The Actuator Display)

(refer to Section 10, page 65 – The Actuator Battery)

Setting Tool Pro Download & Upload Setting Tool Pro includes a feature

stored configuration files can also be

to replicate a setup for multiple units

Using the new features

uploading configuration files from Tool

Accessing the menus

Pro m

user then has 30 seconds to “connect”

Download/Upload Menu structure

dL 01

dC 01

Configuration

UC 01

Upload Configuration

P? Id

entered?

Y

N

10.110 Maintenance, Monitoringand Troubleshooting cont.

Setting Tool ProDownload & Upload

82

69

Downloading and storing IQ Datalogger Files

Press the m Key

Once communication has been

Extract Datalogger screen

Note.

pressing the + or –

Extracting Log screen

Note.

seconds for a full datalogger (2 minutes

[dL Er] Error[dL 01]

The action of downloading the actuator datalogger file will automatically download the configuration file to the Tool.

Downloading and storing IQ Configuration Files

Press the m Key

Once communication has been

Extract Datalogger screen

Note.

PRESS THE k KEY.

Extract Configuration screen

Note.

+ or –

Extracting Configuration screen

Note.

[dL Er]Error,

[dC 01]

10.1 Setting Tool ProDownload & Upload cont.

Extract LogMemory Loc: 01

Extract LogExtracting Data

Extract LogMemory Loc: 01

Extract ConfigMemory Loc: 01

Extract ConfigExtracting Data

70

Uploading a configuration File to an IQ actuator

Note: Actuator must be set to Local when writing configuration data.

Warning: After uploading a configuration file from the tool to the actuator, the actuator basic and configuration set up will be a duplicate of the file set up.

Open and close limit positions and current position are not copied and must be set on each individual actuator.

For access to the Upload Configuration

Press the m Key

[dL 01]

PRESS THE k KEY.

[dC 01]

PRESS THE m KEY.

Upload Configuration screen

Note.

Using the + or –

configuration file is stored and press the

Uploading Configuration screen

Note.

[dL Er]Error

[UC 01]

Write ConfigMemory Loc: 01

Write ConfigWriting Data

10.1 Setting Tool ProDownload & Upload cont.

83

71

Screens can be accessed using the Setting Tool (refer to Fig. 9.1 page 32 for their location)

With Remote selected press the m

Each screen uses bars to indicate the status of a particular control or

changes in the status of its actuator

H1

H2

H3

H4

H5 control inputs and motor

H6 IR Setting Tool communication for

H7

H8

H9

H1 Phase Position Loss Error

Local Controls Error

on

POSITION ERRORBar ON = Current Position Error Present.

processor compares the current position

Re-setting of both actuator limits (refer to

page 29)

BATTERY LOW ON POWER UPBar ON = Low battery detected On Power Up.

If [OS] is selected [On] (default is [OF])

(refer to [OS] page 61).

(refer to page 65)

LOCAL CONTROLS ERRORBar ON = Invalid Local ControlSignals Detected.

signal is detected at the same time this

PHASE LOSSBar ON = Phase Lost (3 Phase Actuators Only).

Help Screens10.2 H1 Factors InhibitingElectrical Operation

72

H2

BATTERY DISCHARGEDBar ON = Battery Discharged.

able to support actuator functions

(refer to Section 10 page 65) and limit positions reset (refer to [LC] and [LO] page 29)

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

ESD SIGNAL ACTIVEBar ON = ESD Signal is present.

actuator to respond in the direction

Configuration screens [A1] to [A5] (refer to Section 9.3 page 36)

H3 Limit

Anti

Limit

Inhibit

CLOCKWISE LIMITBar ON = Actuator has reached clockwise limit of travel.

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

INHIBITBar ON = Actuator inhibited.

Possible Causes:

H4 Remote Remote Maintain 2 Open 1

Close 1

Remote

Remote Remote Open 2 Maintain 1

remote control inputs are designated

REMOTE OPEN 1Bar OFF = Remote Open Signal Present.

continued...

H4 Remote ControlInputs

H3 Actuator Limit and Fault Status

H2 Battery Level andESD Control Input

84

73

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.

H5 Local Stop not Open Selected Interlock

Thermostat Close Tripped Interlock

Local Open Local not not Present Selected

Local Close Remote not not Present Selected

OPEN INTERLOCKBar ON = Open Interlock Active. (Actutator disabled)

Unauthorised Open electrical operation

the interlock function must be selected

CLOSE INTERLOCKBar ON = Close Interlock Active. (Actuator disabled)

Unauthorised Close electrical operation

the interlock function must be selected

REMOTE NOT SELECTEDBar ON = Remote control not selected.Bar OFF = Remote control selected.

LOCAL CLOSE NOT PRESENTBar ON = Local Close signal not present.Bar OFF = Local Close signal present.

LOCAL OPEN NOT PRESENTBar ON = Local Open signal not present.Bar OFF = Local Open signal present.

THERMOSTAT TRIPPEDBar ON = Thermostat tripped.

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

LOCAL NOT SELECTEDBar ON = Local control not selected.Bar OFF = Local control selected.

H5 Remote Interlocks,Local Control Inputs, & T/stat

H4 Remote ControlInputs continued

74

H6 IR Remote Control not Selected

IR Local Local Control Controls

IR Closed Signal not Present

Present Tripped

When actuators are supplied for

The local control functions are then

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

TORQUE SWITCH TRIPPEDBar ON = Torque switch tripped.

“hammering” against the obstruction as a response to a maintained control

To ‘‘de-latch’’ the actuator it must be

(For actuator torque adjustment, refer to [tC ] and [tO] pages 27 and 28)

IR OPEN SIGNAL NOT PRESENTBar OFF = IR Open signal present.

IR CLOSE SIGNAL NOT PRESENTBar OFF = IR Close signal present.

IR LOCAL CONTROL DISABLEDBar OFF = IR Local control enabled.

the IR Setting Tool refer to the option selection screen [Or]

[Or] must be selected to [On]

Ir REMOTE CONTROL NOT SELECTEDBar OFF = Ir Remote control selected

the option selection screen [Or] must be set to [rE] for Remote operation (refer to Section 9.14 page 61)

H7 Open

Limit

Actuator

OPEN LIMITBar ON = Actuator has reached open limit.

CLOSE LIMITBar ON = Actuator has reached Close limit.

ACTUATOR MOVINGBar ON = Actuator moving.

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

(refer to Section 9.2 [r1] page 34 for configuration of ‘‘ S’’contacts)

H6 Torque Switch Status & IR Setting Tool Comms for Vandal Proof Applications

H7 Travel Limits, Centre Column & Remote Indication Outputs

85

75

H8 Position Sensor A

Position Sensor B

POSITION SENSOR A

the bar being ON (and OFF) 12 times

POSITION SENSOR B

the bar being ON (and OFF) 12 times

operation and turn the actuator

sensors OFF:

Sensor B 0 1 1 0 0 Sensor A 0 0 1 1 0

H8 Actuator PositionSensing Devices

76

enable the actuator configuration and onboard datalogger to be reconfigured

Insight can be used to interrogate the

Rotork Setting Tool Pro

configuration and datalogger files

Using the Setting Tool Pro

the same configuration to multiple

To enable communication with IQ Insight the actuator IrDA interface must be enabled.

[On]

use the + or –change to [OF]

PRESS THE KEY.

The use of a notebook PC or PDA with actuators located in hazardous areas will be subject to local regulations. It is the responsibility of the user to seek guidance and permission.

The Rotork Setting Tool and Setting Tool Pro are certified Intrinsically Safe (IS) and therefore can be used in defined hazardous areas (refer to

10.3 IQ InfraredDiagnostic and Configuration

IrDA CommsEnabled

86

77

End user advice on disposal at end of life of the product

Subject Definition Remarks / examples Hazardous Recyclable EU Waste Code Disposal

Oil

companies

In all cases check local authority regulation before disposal

Environmental10.4

78

Weights and Measures11

Actuator Size Nett Weight * Oil Capacity kg/lbs litres/pt.-US

Oil

GreaseSide handwheels.

temperatures use a grease suitable for use at -60°

Linear drive unit.

* NOTE:

87

79

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 1010 0A 10

0000 1011 0B 11

0000 1100 0C 12

0000 1110 0E 14

0000 1111 0F 15

0001 0000 10 16

0001 0001 11 17

0001 0010 12 18

0001 0100 14 20

0001 0101 15 21

0001 0110 16 22

0001 0111 17 23

0001 1000 18 24

0001 1010 1A 26

0001 1011 1B 27

0001 1100 1C 28

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 1000 28 40

0010 1010 2A 42

0010 1011 2B 43

0010 1100 2C 44

0010 1110 2E 46

0010 1111 2F 47

0011 0000 30 48

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 1010 3A 58

0011 1100 3C 60

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 0110 46 70

0100 0111 47 71

0100 1000 48 72

0100 1010 4A 74

0100 1011 4B 75

0100 1100 4C 76

0100 1110 4E 78

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

0110 0100 64 100

0110 0101 65 101

0110 0110 66 102

0110 0111 67 103

0110 1000 68 104

0110 1010 6A 106

0110 1011 6B 107

0110 1100 6C 108

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 1000 78 120

0111 1010 7A 122

0111 1011 7B 123

0111 1100 7C 124

0111 1110 7E 126

0111 1111 7F 127

1000 0000 80 128

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 1010 8A 138

1000 1100 8C 140

1000 1110 8E 142

1000 1111 8F 143

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 1010 AA 170

1010 1011 AB 171

1010 1100 AC 172

1010 1110 AE 174

1010 1111 AF 175

1011 0000 B0 176

1011 0001 B1 177

1011 0010 B2 178

1011 0100 B4 180

1011 0101 B5 181

1011 0110 B6 182

1011 0111 B7 183

1011 1000 B8 184

1011 1010 BA 186

1011 1011 BB 187

1011 1100 BC 188

1100 1000 C8 200

1100 1010 CA 202

1100 1011 CB 203

1100 1100 CC 204

1100 1110 CE 206

1100 1111 CF 207

1110 0000 E0 224

1110 0001 E1 225

1110 0010 E2 226

1110 0011 E3 227

1110 0100 E4 228

1110 0110 E6 230

1110 0111 E7 231

1110 1000 E8 232

1110 1010 EA 234

1110 1011 EB 235

1110 1100 EC 236

1110 1110 EE 238

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 1010 FA 250

1111 1011 FB 251

1111 1100 FC 252

1111 1110 FE 254

1111 1111 FF 255

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

BHD Binary, Hexadecimal andDecimal Conversion Table

80

European – Hazardous areaEExd IIB T4. ATEX (94/9/EC) II 2GD

EExd IIC T4. ATEX (94/9/EC) II 2GD

EExde IIB T4. ATEX (94/9/EC) II 2GD

EExde IIC T4. ATEX (94/9/EC) II 2GD

International – Hazardous areaIECEx. Exd IIB T4

Temperature -20°C to +60°C (-4°F to +140°F)

IECEx. Exd IIC T4

USA – hazardous AreaFM. Class I, Division 1, Groups C & D, Class II, Division 1, Groups E, F & G.

Canada – hazardous Area

Temperature

International Non hazardousWT: Standard watertight, BS EN 60529 :1992, IP68, 7 metres/72 hours.

US – Non hazardousNEMA 4, 4X and 6.

Canada – Non hazardousCSA WT: Canadian Standard Association –Watertight.Wiring and components complying with CSA Enclosure 4 and 4X.

Rotork can supply actuators to national standards not listed above. For details please contact Rotork.

IQ Approvals12

Refer to actuator nameplate for unit specific approval details

88

81

HeadingAA Approved Fuses

82

The default limit for partial stroke is

open limit to the set position and then

To set the closed limit for partial stroke [EL] + or -from Open [EL OP] to Closed [EL CL]

PRESS THE KEY.

[Stored]

the + or -

actuator to perform the partial stroke

PRESS THE KEY.

[Stored]

reasonable amount of time to be set for the partial stroke to complete one

the stroke hasn’t been completed in the

the + or -

PRESS THE KEY.

[Stored]

Partial Stroke – Limit

Appendix A

Partial Stroke – Position Partial Stroke – TimeoutEL EP Et

Partial StrokeLimit: Open

Partial StrokePos: 75%

P.Stroke Timeout300 seconds

89

83

www.rotork.com

Head OfficeRotork Controls LimitedBrassmill LaneBathBA1 3JQ

tel +44 (0)1225 733200fax +44 (0)1225 333467email [email protected]

Local representative:

Rotork Sales and Service

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.Rotork recognises all registered trade marks.

POWTG0409

Pub

lish

ed a

nd

pro

du

ced

in t

he

U.K

. by

Ro

tork

Co

ntr

ols

Ltd

. Heading

ATTENTION: RED PLASTIC PLUGS IN CONDUIT ENTRIES ARE FOR TRANSIT ONLY.FOR LONG TERM PROTECTION FIT SUITABLE METAL PLUGS.

ATTENZIONE: I TAPPI IN PLASTICA ROSSA PER L'ENTRATA CAVI SONO SOLOTEMPORANEI. PER UNA PROTEZIONE PERMANENTE PREGO SOSTITUIRLI CON

APPOSITI TAPPI METALLICI.

ATENCION: LOS TAPONES ROJOS DE PLASTICO EN LAS ENTRADAS DE CABLESON UNICAMENTE PARA TRANSPORTE. PARA PROTECCION PERMANENTE

COLOCAR TAPONES METALICOS APROPIADOS.

ACHTUNG: DIE ROTEN PLASTIKSTOPFEN SIND NUR FÜR DEN TRANSPORT GEEIGNET. FÜR DAVERHAFTEN SCHUTZ SIND DIESE GEGEN GEEIGNETE

BLINDSTOPFEN AUSZÜTAUSCHEN.

ATTENTION: LES BOUCHONS PLASTIQUES ASSURENT UNE PROTECTIONTEMPORAIRE. POUR UNE PROTECTION DEFINITIVE UTILISER DES BOUCHONS

METALLIQUES.

90

Publication E110E issue 05/04

Established leaders in Actuation Technology

IQ & IQT Rangeelectric valve actuatorswith intelligent technology

91

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Rotork Actuation

Rotork Controls Ltd, Bath, UK

Rotork Controls Inc, Rochester, USA

Contents

Features of the IQ range 3

Reliability 4

Intelligent actuation 5

Protection 6

Applications 7

Intelligent communication 8

Rotork Pakscan system control 10

Fieldbus system control 11

Construction 12

Second stage gearboxes 14

Actuator specification 15

Performance summary 16

World leaders in valve control

In the 45 years since the company was founded, RotorkActuation has become a byword for excellence in the fieldof valve, sluice gate and damper actuation products forthe oil, gas, power, water and waste treatment industries- worldwide.

We owe our success to an uncompromising focus on quality at every stage - and at every level - of Rotork’soperations.

From initial site survey, specification and design, throughto materials, manufacturing and testing, installation, commissioning and after-sales service we accept nothingbut the best.

At the heart of the company is an exceptional workforce -the highly trained, forward-thinking engineers, techniciansand support staff who each have a crucial role to play in maintaining Rotork’s unrivalled reputation for innovation,reliability and first class customer support.

Rotork. Established leaders in actuation technology.

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3

Rotork’s IQ intelligent valve actuator range -the best just got better

Rotork’s tried and tested range of IQ intelligent electric valve actuators is now further enhanced- retaining legendary features suchas Rotork’s unique double sealingsystem and ‘non-intrusive’ infraredcommissioning capability by theaddition of the IQT dedicated quarter-turn actuator.

The IQT (IQ quarter-turn) is the resultof ongoing commitment to productdevelopment at the leading edge ofnew technology. The Rotork IQ nowdelivers a complete range of actuatorssuitable for most quarter and multi-turn applications that requirecontrol and indication flexibility, offering end users ever higher standards of performance build qualityand overall value.

The IQ continues to offer all the keybenefits which have made it a worldleader including:

Fit for Life

Whatever the environment, whateverthe duty IQ has become a byword forreliability. Design simplicity, double

sealing with a watertight enclosurecoupled with infra-red set-up andcomprehensive protection systemshave come together to make IQ theworld leader in reliable valve operation. Gain peace of mind andminimise maintenance costs with fitand forget IQ technology.

Simple commissioning

Simple, safe and rapid non-intrusivecommissioning with infra-red control.Actuator settings such as torque levels, position limits, control and indication functions can be accessedand adjusted using the “point andshoot” IQ Setting Tool. The supplied,intrinsically safe (IS) tool is unique to Rotork and allows non-intrusive actuator set-up whatever the environment, power on or power off.

Simple troubleshooting

Active valve, control and actuatoralarm icons are provided on the easyto read illuminated display.

Access comprehensive, real-time, diagnostic help screens with the IQSetting Tool for a full picture of local

and remote control status, actuatorconfiguration and torque against position profiles. The on-board datalogger records operational, alarm andvalve torque profile data providingvaluable information of plant operatingperformance and conditions.

IQ offers a range of powerful features unparalleled in valve actuation including:

● Multi and quarter-turn capability

● Three phase, direct current and single phase actuators

● On-board data logger included as standard

● IrDA compatible for local and remote actuator analysis via PC

● Clear, user friendly controls and indication

● Simplified torque and position control for increased reliability

● Rationalised electronics - “system ona chip” technology

● Comprehensive control and indication flexibility

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4

IQ - simply unmatched for reliability

Protection - the key

Vast experience in the application ofelectric actuators has enabled Rotorkto lead the world in actuator ingressprotection. Situated in environmentsranging from desert to tundra, offshore to underground, where flooding, humidity, extremes of heatand cold, ultra violet and corrosiveatmospheres are normal, actuatorshave to perform unfailingly. Rotorkunderstand that the most importantfactor in the reliability of an actuator isprotection from the environment - insimple terms, the enclosure.

Double sealed for double protection

The IQ enclosure is rated IP68 - 7 metres for 72 hours, NEMA 4/4X/6. Itis completely watertight and dusttightand does not “breathe”. The RotorkDouble Seal system ensures protectionof internal components since they areseparated from the cable gland andterminal compartment by a watertightterminal block. Protection is maintainedduring site hook-up when terminalcovers are removed and is independentof cable gland sealing.

Non-intrusive - sealed for life

IQ covers need not be removed for sitecommissioning. All settings and adjustments are made using the supplied infra-red Setting Tool, including speed setting for the IQT.After assembly in the controlled environment of our manufacturingfacilities, air exchanges are eliminated -all internal components are completelyprotected for life. Non-intrusive control selectors mean there are nomoving shafts penetrating the controlenclosure.

Reliability through simplicity

The IQ combines simplicity of designwhile extending specification and performance.

Torque measurement

An actuators ability to reliably andaccurately determine the force appliedin operating a valve is fundamental in providing valve and actuator protection. The IQ range uses triedand tested technology, proven inindustry. Accurate, repeatable torque measurement is achieved independentof variations in frequency, voltage and temperature.

Position measurement

Reliable process control depends onaccurate positioning of the valve atend of travel and for fluid control, midtravel. The patented IQ non-contactingposition measuring system is the mostsimple yet devised for actuator control.With only one moving part, theresolver converts output centre columnrotation into an electronic signal whichis then compared to position limitsstored within a safe, non volatilememory.

IQT speed control

By use of motor control technologyproven in the AQ range over 20 yearsand now integrated with the IQ “actuator on a chip” the output speedof the IQT can be adjusted withoutaffecting the torque output.

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IQ - big on intelligence

Valve closed Torque and position display

Close torqueset to 40%

Diagnostics display

Actuator display

The IQ incorporates a unique liquidcrystal display developed specificallyfor actuator indication. Large segments allow easy, distance viewingof valve position, torque and diagnostic screens. A unique, diffusedLED backlighting system provides highvisibility in all light conditions. The LCDdisplay is supplemented with positionindication lights, green, yellow and red.

Indication back up

Rotork recognise the need for localand remote position indication at alltimes, even when the actuator is powered down. The IQ incorporates a battery to maintain and update position indication when the mainpower is switched off. The battery also supports power off data loggingand commissioning.

Set-up

Infra-red set up, adjustment andreview using the supplied, intrinsicallysafe IQ Setting Tool allows users accessto the configuration of the actuatorusing the convenient actuator liquidcrystal display.

On screen diagnostic icons

Four dedicated alarm icons are incorporated into the LCD display giving clear indication of valve, controlsystem and actuator alarms.

Help screens

Nine help screens can be accessedwith the IQ setting tool allowing realtime, grouped analysis of control signal status, valve and actuator statusand indication status.

Valve torque indication

Real time viewing of valve torqueagainst valve position can be accessedwith the Setting Tool via the IQ LCD.Analysis of valve operating conditionsis therefore available as standard.

Conditional control

For applications where a high level ofsafety integrity is required the IQ canbe configured for conditional control.In this mode, operation is conditionalon two discrete signals being applied.

Looking at an example of a close valvecommand, by applying a signal to theremote close input and close interlockinput simultaneously the actuator willoperate and close the valve. If onlyone signal is applied, or a signal is lost,the actuator will failsafe by staying put or stopping. When conditionalremote control is configured, the interlock inputs are not required forlocal operation.

Data logging

Every IQ includes an on board datalogger. The data logger captures andstores valve, actuator and control signal operation and status data:

● Valve torque profile, open/closed instantaneous and average torque against valve position

● Number of operations

● Valve and actuator position status log

● Operation signal log

● Actuator control status log

● Statistics

Log data is time and date stampedand can be analysed by playing backin “real time” or on an event by event basis.

The data logger is accessed via theIrDA™ interface to compatible devices,see below. Data logger data can beanalysed with IQ-Insight PC basedsoftware, described in detail on page 8.

IrDA™ communication (IQ-Insight)

IQ supports IrDA™ compatible communication. IQ configuration anddata logger files are accessed via theinfra-red port non-intrusively. Dataexchanges are via IrDA™ with compatible Personal Digital Assistants(PDAs), note books or PCs. IQ-InsightPC software provides the interfacewith the actuator and its on-boarddata logger.

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Full security, full protection

Syncrophase prevents valve damage through incorrect wiring

Rotork’s unique ‘Syncrophase’ automatic phase rotation correctionprevents valve damage through incorrect wiring by ensuring that theIQ three-phase motor is always presented with the correct phase rotation of the power supply.

Single phasing protection**

Also developed to control motor overheating, IQ electronics constantlymonitor all three phases of the powersupply. Should one or more phases belost the control circuit is preventedfrom energising the contactors. Localand remote alarm signals of incomplete supply are offered as standard features.

Motor protection when valve jams

Should a valve jam, the IQ motor isprevented from overheating by a logiccircuit which trips the contactor whenthere is no movement within sevenseconds of a start signal.

IQT uses a 24 volt DC motor. For single and 3 phase* supplied actuatorsthe motor supply is internally providedvia a transformer - rectifier (24 volt DCsupplies - rectifier only). IQT willalways run in the correct direction irrespective of supply type and connection. On loss of one or more ofthe utilised phases (or DC supply pole)the IQT actuator will stop.

IQ thermostatic protection

Two thermostats embedded in themotor windings directly sense temperature, tripping the actuatorcontrol circuit in the event of overheating.

IQT thermostatic protection

Two thermostats are embedded in thetoroid transformer windings providingcomprehensive motor power moduleprotection.

Auto self test and diagnosis (ASTD)

Each time the actuator is powered up, its vital operational circuits automatically self test to ensure correct operation. In the unlikely event that a fault is diagnosed the information is automatically presentedusing the display icons. At the sametime, actuator operation can be inhibited to enable site investigation.

Instant reversal protection

An automatic time-delay circuit avoidsthe shock loads which may causeunnecessary wear to valve stems andgearboxes when an actuator is orderedto reverse direction ‘instantaneously’.The circuit also limits current surgesthrough the contactor.

* Actuator utilises 2 phases only - refer to circuit diagram.** IQ 3 phase only.

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Customised features

Floor mounting for easy remotecoupling

Floor stands with upward or downward stubshafts are available forcoupling, via customer shafts and universal joints, to remote valves.

Linear output drive assemblies

For applications requiring an actuatorwith a linear output, a leadscrewarrangement can be fitted to the baseof the standard IQ actuator.

Damper actuators

Single blade and multi vane damperscan be motorised either by direct connection to the damper spindle orby lever arm.

Valve stem expansion

The stems of positive seating valves,such as solid or flexible wedge gatesmay be subject to significant expansion when used in high servicetemperature applications resulting indamaged or leaking valves. The effectsof this expansion or contraction maybe overcome by fitting the Rotorktemperature compensator to the output of the IQ actuator.

For further details see publicationE152E.

Even though Rotork’s standard IQ actuator offers wide ranging control and indication flexibility, avariety of customised features canbe specified to reflect individualcustomer requirements. Gearboxesfor multi-turn and part-turn valvesLarge or slow moving gate andglobe valves can be motorisedthrough thrust taking bevel or spur gear operators on which theelectric actuator is mounted. IQTprovides direct operation of smallto medium sized quarter-turnvalves up to 2000Nm. IQ actuatorscan also be fitted with part-turnworm and wheel gearboxes toprovide increased torque atreduced speeds for the operationof part-turn valves. A sizing program for both part-turn andmulti-turn applications is available on CD ROM.

IQTF (full turn) actuators

For non-thrust, multi-turn, slow speedapplications, the IQTF provides a reliable solution with the same generalspecification as the IQT range.

For further details please contactRotork.

Fireproofing and extreme cold

Fully operational at temperatures of up to +70°C, the standard IQ rangeactuator can be made operable for up to thirty minutes in a fire (whentemperatures may quickly climb toover 1000°C) through the use ofboxes, blankets or intumescent coating, as specified by the customer.

Modifications can also be implementedto allow cold temperature operation as low as -50°C.

For further details see publicationS310E.

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Intelligent communication - lifetime support

Above:Actuator torque display using IQ-Insight software

Lifetime support

Rotork understands its customers need for back up. The costs andpenalties of plant downtime, delayedcommissioning schedules and inappropriate maintenance are toohigh to allow for inefficient support.With IQ - IrDA™ (Infra-red DataAssociation) communication and theonboard datalogger, the IQ now offersunrivalled support to provide completeproduct back up with analysis andconfiguration. With Rotork’s unrivalledworldwide service network expertadvice is always close to hand.

Remote diagnosis - IrDA™

The IQ utilises IrDA™ communicationfor fast, safe, non-intrusive andstandardised data exchange. Actuatorset-up configuration can be analysedand if required changed. As every IQincludes an on board data logger,operational data such as valve torqueprofiles, actuator events and statisticscan be downloaded for detailed investigation. Data logger informationcan also be relayed to a user site basevia an IrDA™ compatible PDA. Afteranalysis, any changes to the actuatorset-up configuration can be relayedback to the actuator.

PC tools - IQ-Insight - Pocket-Insight

IQ-Insight PC software is a graphicaluser interface allowing all IQ set-upconfiguration and data logger information to be reviewed analysedand reconfigured. The visually interactive application is browserbased, running under Microsoft orother internet browser systems.Familiar tools such as linking, bookmarking, “back” and “forward”controls, make analysing the datafrom an IQ simple and fast. LaptopPC’s with IrDA™ interface (or serialport with IrDA™ interface) running IQ-Insight can be directly “connected” to an actuator located in the field toallow set-up, adjustment and analysis.

Alternatively, using a PDA running IQPocket-Insight, data can be uploadedfrom the actuator and later downloaded to a PC.

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Rotork help - online around the world

Rotork has a comprehensive servicenetwork worldwide to provide youwith in-country support. Rotorktrained technicians working from ournetwork of offices and centres ofexcellence are available to offer immediate assistance.

To contact Rotork, visit the website at www. rotork.com

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Rotork Pakscan system control

Rotork Pakscan - the total control solution

Whether you need remote control ofjust a small number of motorisedvalves or full automation of a plantwith thousands of instruments andcontrol elements, Pakscan can helpyou to achieve significant savings interms of both time and money.

That’s because Pakscan is capable ofcontrolling and monitoring up to 240field devices using a simple shielded,twisted pair cable loop instead of amulti conductor cable for each fielddevice. The system can also gatherimportant digital and analogue plantdata when its master station(s) arelinked to the double sealed field unitwhich is fully integral to each Rotorkactuator.

Together with Pakscan’s ability to communicate directly with a PLC orDCS system via an RS485 or RS232link, its overall simplicity keeps customers’ design work to a minimum.


Rotork Pakscan IIE Master Station

Available in single or hot standby configurations the Pakscan IIE masterstation can control 240 field devicesover a loop distance of up to 20km -without the need for signal repeaters. The Pakscan IIE is mounted in a133mm high 19” rack and each master station comes complete withdual host communication ports (RS232and RS485), a user interface LCDscreen and operator keypad. The rackcan house a single unit, two singleunits operating independently or a HotStandby system. The Hot Standby version of the IIE features two identicalmodules and transfer between themain and standby is transparent and automatic in the event of a component failure.


Rotork Pakscan IIS SequencerMaster Station

The Pakscan IIS master station encompasses the proven features ofthe Pakscan 2 wire control systemwith the logic and programmabilitymore commonly found in a PLC toprovide a fully featured sequence andinterlock control package. Easily programmed by ‘fill in the box’ menusthe Pakscan IIS can quickly be madeready to run your plant. Located in thefield close to the process, Pakscan IISpermits control and monitoring of upto 32 field units.


In-Vision - powerful, user-friendly

In-Vision is a SCADA (SupervisoryControl And Data Acquisition) software application for full, userfriendly control of complex installations such as oil storage depotsand water treatment plants wherethere can be a high number of actuators and process signals to control and display.

Working with Pakscan and running ona standard PC, In-Vision offers a highlyflexible series of graphic displays andcontrols that allow the plant managersto view and control all aspects of theirprocess at a fraction of the cost ofother comparable systems.


Rotork Pakscan - system advantages

● Up to 240 field units per master station

● Loop distance up to 20km (240 units) without repeaters

● Separate operator controls without burdening the DCS

● Continues operation even with a field cable failure

● Simple, easy to install, proven reliability

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Modbus®

Rotork actuator control solutions alsointerface to a wide range of communication and control systems,including those covered by the majorinternational standards.

Multiple fieldbus connectivity

In addition to offering full compatibility with Pakscan, IQ actuators can be specified to interface seamlessly to many other fieldbus digital control systems. Open fieldbusprotocols such as Profibus, FoundationFieldbus, DeviceNet and Modbus areall available within the IQ actuatorcontrol option range.

This is achieved simply and cost effectively through fitting an appropriate Rotork manufactured circuit board module inside the actuator’s electrical housing - normallyat the time of production. Module commissioning and setup is carriedout using a combination of the IQSetting Tool and the network commissioning tools used for the chosen protocol.

Fieldbus system control

Rotork IQ and IQT actuators are fully compatible with the following fieldbus communication systems:

Central control of up to240 units on a single loop

R O T O R K PA K S C A N

Master Station

2 wire (single pair) fault tolerant and redundant system

DCS

Choose from: Profibus,Modbus, Foundation Fieldbus, DeviceNet

F I E L D B U S

Interface

2 wire (single pair) highway requires repeaters after 32 devices

DCS

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Advanced engineering

1 Hand operation

Direct drive handwheel (or gearedhandwheel on larger sizes and IQT) to provide reliable emergency manualoperation in the event of a powersupply failure. With padlockable*hand/auto clutch for safe operationeven when the motor is running.

Note: power operation always haspreference unless hand/auto lever ispurposely locked into ‘hand drive’.Lost motion ‘hammerblow’ effect isprovided with both direct and independently geared handwheels.

2 Non intrusive setting

All actuator settings and diagnosticsare made through the sealed indication window. It is not necessaryto remove electrical covers exposingthe integral controls on site.

3 Local controls

Local controls and padlockable*Local/Stop/Remote selector switchoperate internal reed switches, avoiding penetrating shafts whichwould have to be sealed to preventmoisture ingress.

4 Position control

Hall effect magnetic pulse systemaccurately measures and controls thestroke of the actuator without usinggears and switches.

2

3

5

6

1

IQ

IQT

IQ

IQT

4

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5 Terminal compartment

Separately sealed terminal compartment ensures the integrity ofthe electrical equipment even whenthe terminal cover is removed duringsite wiring.

6 IQ motor and drive

Motor shaft and worm shaft separateto facilitate simple actuator speedchange. Low inertia high torquemotor. The motor produces peaktorque rapidly after starting but withvery little overrun when de-energized.The winding thermostat providesaccurate temperature sensing independent of ambient temperatureconditions to optimize the motor’sthermal capacity. The motor driveincludes a lost motion ‘hammerblow’to assist in unseating tightly shutvalves. Single worm and wheel driverunning in an oil bath for maximumlife with ambient temperature tolerance.

IQT motor

High efficiency compact unit with aproven reliability record in valve actuation applications over 20 years.Integrated speed control allows output speed adjustment over a 4:1speed range.

7 Thrust base

Cast iron, water sealed bearings.Easily removable drive bushing for machining to suit valve stem for convenient valve adaptation.

*Suitable for 6mm / 1/4 inch padlock

1

1

2

2

3

3

4

4

5

6

5

7

7

6

IQ

IQT

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Gearboxes

Multi-turn output - IB and IS Range

For multi turn applications the Bevel(IB) and spur (IS) gear combinationsare available, where screwed or keyedstems are used to operate the valve. IQ - IB combinations are available upto 8,135Nm torque and 1,557kNthrust output. IQ - IS combinations areavailable up to 43,386 Nm torque and3,342kN thrust output.

Key features:

● Totally enclosed, fully sealed and grease filled for life

● Removable output drive coupling for machining

● Comprehensive gear ratios combinedwith a selection of auxiliary input spur/bevel gear reducers

● Optional input flanges

● Optional twin pinion units for secondary drive (IB)

● Upward or downward drive option (IS)

Quarter-turn output

For torque output up to 2000Nm IQTprovides direct quarter-turn output.For part-turn applications that requiretorques in excess of 2000Nm or whereincreased thrust/torque at reducedoperating speed is required, Rotorkproduce a range of gearboxes. Withthe IW range of gearboxes torque outputs up to 137,000Nm are available.

Key features:

● Totally enclosed, fully sealed and greased filled for life

● Removable output drive coupling formachining, repositionable baseplate facility

● Adjustable mechanical stops (at 0° and 90° +/- 5°)

● Comprehensive gear ratios combined with a selection of auxiliary input spur gear reducers

● Optional input flanges

Modulating and submersible gearboxforms are available. As standard, gearboxes are despatched painted thesame colour as the actuator.

Gearbox summary: Quarter-turn 90˚

Torque: Nm lbs ft 2,000 1,476 137,000 107,000

Actuator type: IQT IQ + IW Worm Gearbox

Gearbox summary: Multi-turn

Torque: Nm lbs ft 3,000 2,200 8,135 6,000 43,386 32,000

Thrust: kN Lbs 44 10,000 350 1,557 3,342 750,000

Actuator type: IQ IQ + IB Bevel Gearbox IQ + IS Spur Gearbox

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The following pages contain detailson performance and specification forthe Rotork IQ range of actuators.Please use the contents table belowto help access the information yourequire.

1 Performance summaries p16

2 Actuator Drive Couplings p20

3 Introduction p23

4 Mechanical p23

4.1 Enclosure p23

4.2 Valve/actuator interface p24

4.3 Handwheel p24

4.4 Lubricant p25

4.5 Finish p25

5 Electrical p25

5.1 Power supplies p25

5.2 Control p25

5.3 Indication, monitoring and

data logging p27

5.4 Fieldbus system control p28

5.5 Protection p28

5.6 Actuator set-up p28

6 Actuator Components p29

6.1 Motor p29

6.2 Power module p29

6.3 Control module p29

6.4 Torque and position control p29

6.5 Conduit entries, terminals

and wiring p29

7 Design Specification p30

7.1 Design life p30

7.2 Frequency of operation p30

7.3 Operating temperature p30

7.4 Vibration p30

7.5 Safety integrity p30

7.6 Noise p30

Actuator specification - contents

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IQ 3 phase performance summary

IQ10 34 34 34 34 34 34

25 25 25 25 25 25

Performance data

Actuator output speeds

rpm at 50 Hz 18 24 36 48 72 96 144 192

rpm at 60 Hz 21 29 43 57 86 115 173 230

Actuator size Torque** Nm Ft lbf

IQ12 81 81 81 68 48 41

60 60 60 50 35 30

IQ18 108 108

80 80

IQ20 203 203 203 203 176 142 102*

150 150 150 150 130 105 75*

IQ25 400 400 298 244 244 230 149*

295 295 220 180 180 170 110*

IQ35 610 610 542 474 474 366 257*

450 450 400 350 350 270 190*

IQ40 1020 1020 845 680 680 542 406*

750 750 625 500 500 400 300*

IQ70 1490 1490 1290 1020 1020 745 645* 542*

1100 1100 950 750 750 550 475* 400*

IQ90 2030 2030 1700 1355 1355 1020 865* 730*

1500 1500 1250 1000 1000 750 640* 540*

IQ91 1355* 1355*

1000* 1000*

IQ95 3000

2200

* Due to the effects of inertia and drive nut wear, speeds not recommended for direct mounted gate valve applications.

** Torque rating is maximum torque setting in both directions. Stall torque will be 1.4 to 2.0 times this value depending on speed and voltage. If maximum torque is required for more than 20% of valve travel, refer to Rotork.

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IQ single phase and IQ DC

IQS12 65 60 45 40 30 25

48 44 33 30 22 18

IQ single phase - performance data

Actuator output speeds

rpm at 50 Hz 18 24 36 48 72 96 144

rpm at 60 Hz 21 29 43 57 86 115 173


IQS20 165 130 130 125 100 80 60

122 96 96 92 74 59 44

IQS35* 450 400 350 320 230 190 135

332 295 258 236 170 140 100

* IQS35 not available at 115v. Actuator output speed 144/173 rpm is not recommended for direct mounted gate valve applications.

** Torque rating is maximum torque setting in both directions. Stall torque will be 1.4 to 2.0 times this value depending on speed and voltage. If maximum torque is required for more than 20% of valve travel, refer to Rotork.

IQD10 34 34 31 27

25 25 23 20

IQ DC - performance dataActuator output speeds

rpm 18 24 36 48


IQD12 68 68 61 54

50 50 45 40

IQD18 108

80

IQD20 163 163 136 108

120 120 100 80

IQD25 305 305 257 203

225 225 190 150

DC supply voltage 24V 48V 110V

IQD10 ✔ ✔ ✔

IQD12 ✘ ✔ ✔

IQD18 ✘ ✔ ✔

IQD20 ✘ ✘ ✔

IQD25 ✘ ✘ ✔

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IQ performance summary

Group ‘B’ couplings (non-thrust)

Bore diameter

Mechanical data

Actuator size IQ IQS IQD � 10 20 35 40 70 90 91 95

12 25

18

Flange size ISO 5210 F10 F14 F16 F25 F25 F30* F25 F30

MSS SP - 102 FA10 FA14 FA16 FA25 FA25 FA30* FA25 FA30

Thrust rating kN 44 100 150 220 220 334 N/A 445

lbf 10,000 22,480 33,750 50,000 50,000 75,000 N/A 100,000

Rising mm 32 38 54 64 70 70 N/A N/A

ins 11/4 11/2 21/8 21/2 23/4 23/4 N/A N/A

Non-rising mm 26 32 45 51 57 57 N/A N/A

ins 1 11/4 13/4 2 21/4 21/4 N/A N/A

Z Rising mm N/A 51 67 N/A N/A N/A N/A N/A

ins N/A 2 25/8 N/A N/A N/A N/A N/A

Type ‘B1’ (fixed bore) mm 42 60 80 100 100 120 100 N/A

Type ‘B3’ (fixed bore) mm 20✝ 30✝ 40✝ 50 50 50 50 N/A

Type ‘B4’ (maximum) mm 20✝ 30✝ 44✝ 50 60 60 60 N/A

ins 3/4 11/4 13/4 2 21/4 21/4 21/4 N/A

Handwheel ratio Standard Direct Direct Direct Direct 15:1 15:1 15:1 15:1

Optional 12:1 13.5:1 22.5:1 15:1 or 30:1 45:1 30:1 45:130:1

Group ‘A’ couplings (thrust)

Stem acceptance diameter

Type ‘A’ (maximum)

Type ‘Z’ - ‘Z3’

* IQ90 with B3 and B4 couplings have flange size F25. ** Weight will be dependent on optional equipment fitted.✝ For actuator sizes IQ10 to IQ35 when required to drive shafts or stems having any axial movement, a type ‘A’ coupling must be used.✝✝ Utilises Z3 form drive coupling.

Approximate weight** kg 27 46 69 190 190 200 200 200

lbs 60 101 152 418 418 440 440 440

Z3 Rising mm 32 51 67 73 83 83 N/A 83

ins 11/4 2 25/8 27/8 31/4 31/4 N/A 31/4

Non-rising mm N/A 38 51 57✝✝ 73✝✝ 73✝✝ N/A 73✝✝

ins N/A 11/2 2 21/4✝✝ 27/8✝✝ 27/8✝✝ N/A 27/8✝✝

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IQT quarter-turn performance summary

Performance and mechanical data

Actuator IQT125 IQT250 IQT500 IQT1000 IQT2000

Torque

Max Nm 125 250 500 1000 2000Min Nm 50 100 200 400 800

Max Ft lbs 92 185 369 738 1476Min Ft lbs 37 74 148 295 590

Operating time

90˚ Min 5 8 15 30 6090˚ Max 20 30 60 120 120

Flange

ISO 5211 F05* F07* F10 F07* F10 F10 F12 F14* F14

MSS SP-101 FA05* FA07* FA10 FA07* FA10 FA10 FA12 FA14* FA14

Weight

Kg 22 22 22 37 37

lbs 49 49 49 82 82

Couplings**Spindle acceptance

Bore & key max mm 22 28 42 28 42 42 60 60Bore & key max ins 0.87 1.1 1.65 1.1 1.65 1.65 2.36 2.36

Square AF max mm 14 19 32 19 32 32 41 41Square AF max ins 0.56 0.75 1.25 0.75 1.25 1.25 1.62 1.62

Handwheel

Turns for 90˚ 80 80 80 80 80

Angular adjustment

(nominal) degrees 80 - 100 80 - 100 80 - 100 80 - 100 80 - 100

* Optional flanges F05, FA05, F07 and FA07 use a base adapter plate. Required base type must be specified.

** Couplings are supplied blank for machining by valve maker.

IQT 24V DC (17-37 Volts) Performance

Torque outputs for 24V DC are the same as above, however speed varies with load.

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IQ actuator drive couplings

2 Actuator drive couplings

The IQ range features two actuator base designs - a removable base for the IQ10, 12,18, 20, 25 and 35 sizes and an integral base for IQ40, 70, 90, 91and 95. Both arrangements areavailable with flanges and couplings which comply witheither ISO 5210 or MSS SP-102.

Actuators IQ10 IQ12 IQ18 IQ20 IQ25 IQ35

Removable thrust base

T h r u s t

N o n - T h r u s t

Type Z3for sizes IQ10 to 35increased stem acceptanceand reach

Type Zfor sizes IQ20 to 35increased stem acceptance

Type Afor sizes IQ10 to 35

Type B1for sizes IQ10 to 35large fixed borewith ISO standardbore and keyway

Type B3for sizes IQ10 to 35fixed bore withISO standard boreand keyway

Type B4for sizes IQ10 to 35blank drive bush for machiningby customer

Removable non-thrust base

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Thrust bearings

Both type ‘A’ and ‘Z’ couplings featurean associated thrust bearing. In thecase of the removable thrust base thisis fully sealed and lubricated for life; inthe integral base design this is lubricated by the actuator gearcase oilbath. Both integral and removablethrust bases are designed to retain alldeveloped thrust reaction forces without any load appearing on theactuator gearcase.

Actuators IQ40 IQ70 IQ90 IQ91 IQ95

Standard centre columnwith thrust bearing

T h r u s t

N o n - T h r u s t

Non-thrust centre column

Type Z3for sizes IQ40, 70, 90and 95 increasedstem acceptanceand reach

Type Afor sizes IQ40, 70and 90

Type B1for sizes IQ40, 70and 90 large fixedbore with ISO standard bore and keyway

Type B3for sizes IQ40, 70,90 and 91 fixedbore with ISO standard boreand keyway

Type B4for sizes IQ40, 70,90 and 91 blank drive bushfor machiningby customer

Position 1

Position 2

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IQT actuator drive couplings

Drive couplings*The easily removable drive bushis supplied blank for machining to suit valve stem for convenientvalve adaption. The IQT basedesign and drive couplings comply with either ISO 5211 orMSS SP-101.

Actuators IQT125 IQT250 IQT500

F10/FA10for sizesIQT125/250/500

F07/FA07for sizes IQT125/250

F05/FA05for size IQT125

*bore and key is for illustrative purposesonly. Drive bushes are supplied blank asstandard.

Actuators IQT1000 IQT2000



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Standard specification

3 Introduction

IQ actuators are self contained units for local and remoteelectrical operation of valves. Comprising an electric motor,reduction gearing, reversing starter with local controls, turnsand torque limitation with electronic logic controls and monitoring facilities, all housed in a double-sealed watertight enclosure to IP68 7 metres-72 hours, NEMA 4,4X and 6.

All torque and turns settings and configuration of the indication contacts are effected using the non-intrusive,hand held infra-red, IQ Setting Tool, which is included witheach order.

The following specification covers standard features andavailable optional features. Options selected must be specified with enquiry.

4 Mechanical4.1 Enclosure and ambient

temperatures

All IQ actuator hazardous and non-hazardous area enclosures are built toa watertight standard. Through theuse of non-intrusive commissioningand site adjustment using the supplied infra-red IQ Setting Tool, thehermetic, factory-sealed enclosureprotects internal components for lifeas covers never need removing. Theterminal compartment is sealed fromother areas by the Rotork doubleseal, maintaining watertight integrityeven during site connection.

Actuators are available with the following enclosure types for whichthe ambient working temperatureranges are stated. Where option temperatures are indicated, changesto some actuator components arerequired and therefore the temperature requirement must bespecified. Hazardous area approvalsfor other country standards are available, please apply to Rotork.

The IQ range is built in accordancewith the following standards:

WT: Standard watertight,IEC 60529 (1989-11), IP68 7 metres/72 hours, NEMA 4, 4X and 6.Temperature -30°C to +70°C (-22°F to +158°F). *Option -40°C to +70°C (-40°F to +158°F).*Option -50°C to +40°C (-58°F to +104°F).

European - Hazardous Area

EExd IIB T4. ATEX (94/9/EC) II 2GD:CENELEC Norm EN50014 andEN50018.Temperature -20°C to +70°C (-4°F to +158°F). *Option -30°C to +70°C (-22°F to +158°F).*Option -40°C to +70°C (-40°F to +158°F). *Option -50°C to +40°C (-58°F to +104°F).

EExd IIC T4. ATEX (94/9/EC) II 2GD:CENELEC Norm EN50014 andEN50018.Temperature -20°C to +70°C (-4°F to +158°F).

Below:Pocket IQ-Insight software tool used to download ‘data logger’ file.

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EExde IIB T4. ATEX (94/9/EC) II 2GD: CENELEC Norm EN50014, EN50018and EN50019.Temperature -20°C to +70°C (-4°F to +158°F).Option -30°C to +70°C (-22°F to +158°F).Option -40°C to +70°C (-40°F to +158°F).Option -50°C to +40°C (-58°F to +104°F).

EExde IIC T4. ATEX (94/9/EC) II 2GD:CENELEC Norm EN50014, EN50018and EN50019.Temperature -20°C to +70°C (-4°F to +158°F).

International - Hazardous Area

IECE. Exd IIB T4:IEC60079-0 and IEC60079-1 for ExdIIB T4.Temperature -20°C to +60°C (-4°F to +140°F).

IECE. Exd IIC T4:IEC60079-0 and IEC60079-1 for ExdIIC T4.Temperature -20°C to 60°C (-4°F to +140°F).

USA - Hazardous Area

FM. Class 1, Division 1, Groups C,D, E, F, G hazardous areas:Factory Mutual - Explosionproof toNEC Article 500.Temperature -30°C to +60°C (-22°F to +140°F).Option -40°C to + 60°C (-40°F to +40°F).Option -50°C to +40°C (-58°F to +104°F).Alternative for Group B hazardousarea. Temperatures as for GroupsC and D.

Canada - Hazardous Area

CSA EP. Class 1, Division 1, GroupsC and D hazardous areas:Canadian Standard Association -Explosionproof.Temperature -30°C to +70°C (-22°F to +158°F).Option -50°C to +40°C (-58°F to +104°F).Alternative for Group B hazardousarea. Temperatures as for GroupsC and D.

International - Non Hazardous

WT: Standard watertight, BS EN60529 :1992, IP68, 7 metres/72 hrs.Temperature -30°C to +70°C (-22°F to +158°F).Option -40°C to +70°C (-40°F to +158°F).Option -50°C to +40°C (-58°F to +104°F).

US - Non Hazardous

NEMA 4, 4X and 6:Temperature -30°C to +70°C (-22°F to +158°F).Option -40°C to +70°C (-40°F to +158°F).Option -50°C to +40°C (-58°F to +104°F).

Canada - Non Hazardous

CSA WT: Canadian StandardAssociation -Watertight. Wiringand components complying withCSA Enclosure 4 and 4X:Temperature -30°C to +70°C (-22°F to +158°F). Option -40°C to +70°C (-40°F to +158°F).Option -50°C to +40°C (-58°F to +104°F).

Rotork can supply actuators tonational standards not listedabove. For details please contactRotork.

4.2 Valve/actuator interface

The range of IQ actuators is availablewith mounting base and output drivecouplings conforming to internationalstandard ISO 5210 or USA standardMSS SP-102. IQT actuators are available with mounting base andoutput drive couplings conforming toISO 5211 or US standard MSS SP-101. Applications for which thevarious types of couplings have beendesigned are outlined on pages 20-22

4.3 Handwheel

Handwheels are provided to allowmanual operation of the valve duringelectrical power interruption.

IQ10 - IQ40 Direct acting top mounted handwheel. Option: sidemounted geared handwheels.

IQ70 - IQ95 Side mounted gearedhandwheel. Option: alternative gearratios.

IQT all sizes. Side mounted gearedhandwheel.

During electric operation of the actuator the handwheel is mechanically disengaged from thedrive. To engage handwheel operation, the hand/auto selectionlever is depressed and released afterwhich handwheel operation remainsselected. When electrical operationtakes place, the actuator will automatically return to motor drivewithout lever or handwheel kickback.

The hand/auto selection lever incorporates a facility for locking inthe hand or auto positions using a6mm diameter hasp padlock (notsupplied by Rotork), preventingengagement of motor drive (locked inhand) or engagement of handwheeldrive (locked in auto). Emergency disengagement of motor drive can beselected by depressing and holdingthe lever during electric operation.

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4.4 Lubrication

IQ and IQT actuators are factory filledfor life with premium quality gear oilspecified as SAE 80/90 EP for IQ andDextron 2 for IQT. Oil lubrication out-performs grease over the IQ temperature range -30°C to +70°C,with none of the problems associatedwith grease such as separation andtunneling. Rotork have used this samegrade of lubricating oil for 40 years.

Lubrication options

Food grade lubricant

IQ and IQT actuators may be suppliedwith the gearcase filled with HydraLube GB Heavy food grade lubricant.This lubricant is a synthetic non-aromatic hydrocarbon mixture withPTFE and other additives. It does notcontain chlorinated solvents. Greaseused in assembly and thrust bearingsis Hydra Lube WIG Medium-NLGI-123.

Extreme temperature service

Where actuator service requires operation outside of -30°C to +70°Calternative lubricants are available,please apply to Rotork.

4.5 Finish

All IQT and IQ actuators up to sizeIQ35 are finished in polyester powdercoating, colour silver grey. Actuatorssize IQ40 and above are finished inair-dried urethane reinforced syntheticalkyd resin colour, silver grey. For fullspecification of paint finish see publication E151E.

Finish options

Colour: Other colours may be speci-fied, please apply to Rotork.

Offshore: 2 pack epoxy coatings areavailable for extreme environmentalconditions, please apply to Rotork.

5 Electrical5.1 Power supplies

IQ and IQT actuators are suitable for operation with the following threephase, three wire power supplies:

50Hz200, 220, 240, 380, 400, 415, 440,480, 500, 550, 660 and 690 volts

60Hz200, 208, 220, 230, 240, 380, 400,440, 460, 480, 575, 590, 600, 660and 690 volts

The required nominal operating voltage must be specified at time oforder.

Actuator performance is guaranteedwith a voltage tolerance +/-10% andfrequency tolerance +/-5Hz. Actuatorsare capable of starting and runningup to speed with a maximum 15%volt drop.

Uninterruptable power supplies

Standard actuators can be operatedon UPS systems providing the abovespecified tolerances are not exceededand waveforms, harmonics, spikesetc. adhere to recognised supply standards such as EN50160. For moreinformation refer to publicationE130E.

Power supply options

IQS and IQT single phase

Available for standard single-phasevoltages: 50Hz: 110, 115, 120, 220, 230 and240 volts60Hz: 100, 110, 115, 120, 208, 220,230 and 240 volts

IQD and IQT DC

Available for the following DC supplies:IQD: 24, 48 and 110 voltsIQT: 24 volts

Non-standard voltagesActuators can be supplied to operateon power supply voltages other thanthose quoted above. Please apply toRotork.

Non standard tolerances

Where voltage and/or frequency variations may be experienced outsidethose quoted above, or where operation under large volt drop conditions may be required pleaseapply to Rotork.

5.2 Control

Local control

Non-intrusive selectors are providedon the actuator electrical controlcover, one for Local/Stop/Remoteselection, pad-lockable in each position, and the other for Open/Close control. Controls may be rotatedto suit actuator orientation.

Local control may be selected tooperate using the supplied IQ SettingTool. The Setting Tool incorporatesdedicated open, stop and close buttons and will operate over a nominal distance of 0.75 metres fromthe display window.

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Local control option

Vandal resistant

Selectors removed, indication windowwith removable cover, control oflocal, stop and remote selection andlocal open and closed control is viathe supplied IQ Setting Tool.

Remote control

There are six control inputs forremote control:

Open, closed, stop/maintain.

Emergency shut down (ESD).

Open interlock and closed interlock.

Control can be connected for maintained or push to run, (inching)control.ESD signals must be derivedfrom a stayput contact. For moreinformation refer to publicationE120E.Control inputs are opto-isolated interfaces with a surge immunity of2kV. Control is positive switchingnegative earth, internally fed from theactuator 24V DC customer supply orfrom external supplies within theranges 20-60V AC or DC or 60-120VAC.

ESD can be configured off, activehigh or active low, to close or openthe valve, with or without automaticmotor thermostat bypass*. ESD willoverride any local or remote signalsthat may be active. If required ESDcan be configured to override localstop, interlocks or the optional interrupter timer. The ESD input operates from a separate commonallowing isolation between the ESDcontrol system and operational control systems.

*Bypassing the motor thermostat will invalidatehazardous area certification.

Remote control can be configured so that the open signal and openinterlock (or closed signal and closedinterlock) can be combined to form aremote open (or closed) signal thatcan detect single faults. When configured, interlocks will not beactive during local control. For moreinformation refer to publicationE120E.

Remote control options

Negative switching

For remote control systems where thenegative pole of the remote controlcircuit supply is switched.

External control circuit supplies

For control with supplies in the range60 - 125V DC and 230V AC an alternative control circuit option isavailable.

Analogue Proportional Control

The Rotork Folomatic proportionalcontroller enables the actuator toautomatically position a valve in proportion to an analogue current,voltage or potentiometric signal.Signal ranges: 0-5, 0-10, 0-20 or 4-20mA. 0-5, 0-10 or 0-20V.

Positioning can take place over thewhole valve stroke or if required, aset portion of stroke. By incorporatinga remote manual/remote auto controlselector in the control scheme, proportional control can be over- ridden allowing standard remote control operation to take place whenmanual intervention is required (seeabove). The Folomatic can be configured to failsafe stayput, openor closed on loss of analogue signal.

Hydraulic shock/surge protectionIQ

Where the operating time of thevalve must be increased to preventhydraulic shock or water hammer, or to prevent surges, the RotorkInterrupter Timer option can beincluded. Pulsed operation with independently adjustable on and offtime periods in the range 1-99 seconds can be selected to operateover any portion of the closing oropening valve stroke, effectivelyreducing valve speed. On/Off timeperiod range may be extended whenconfiguration is carried out with theIQ-Insight PC tool. The interruptertimer is active for both local andremote control.

Hydraulic shock/surge protectionIQT

The IQT actuator allows the outputspeed to be adjusted with the SettingTool. Refer to performance summary,page 19. Speed control over 4:1 ratiois available and settable non intrusively. The IQT also includes theInterrupter Timer option (as above)for extended operating times.

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5.3 Indication, monitoring and data logging

Local

A back-lit liquid crystal display givesdigital indication from fully open tofully closed in 1% increments. ThreeLED’s coloured red, green and yellowfor indication of open, close andintermediate positions respectively arealso provided. The display includesfour icons for rapid diagnosis of valvealarm, actuator alarm, control systemalarm and actuator battery status.

With the supplied IQ Setting Tool,actuator torque plus position can bedisplayed allowing the valve torqueagainst position to be monitored inreal time. Help screen diagnosis isavailable for monitoring valve, actuator and control system status.The local display can be rotated tosuit actuator orientation. LED colourscan be reversed. Please specify withorder.

Remote

Four latching volt free contacts, S1,S2, S3 and S4 are provided eachindependently configurable using thesupplied IQ Setting Tool to signal oneof the following:

Valve Positionfully open, fully closed or intermediatepositions (0-99% open).

StatusValve opening, closing, moving (continuous or pulsing signal),Local stop selected, local selected,remote selected, open or close interlock active, ESD active.

Valve AlarmsMotor tripped on torque in mid travel, motor tripped on torque goingopen, going closed, pre-set torqueexceeded, valve jammed, actuatorbeing operated by handwheel.

Actuator alarmsLost phase (3 phase IQ only), customer 24V DC (120V AC) supplylost, battery low, internal failuredetected, thermostat tripped.

Each contact can be configured toeither ‘normally open’ or ‘normallyclosed’ and rated at 5mA to 5A,120V AC, 30V DC.

Monitor relay

An independent relay with a volt-freechangeover contact for monitoringactuator electrical availability.

Contact rating 5mA to 5A, 120V AC,30V DC. The relay will de-energiseunder any of the following conditions:

Loss of one or more of the powersupply phases.

Loss of control circuit supply.

Local control selected.

Local stop selected.

Motor thermostat tripped.

Data logger

The on board data logger allowsinfra-red, IrDA( (Infra-Red DataAssociation) standard, download ofhistorical actuator/valve performancedata to PC or via an IrDA compatiblePDA.

For hazardous areas the intrinsicallysafe Rotork Communicator tool isavailable. Rotork IQ-Insight PC software allows data logger information of operational events andstatistics all time and date stampedplus valve torque/position profiles,both last operation and historicaltrends, all to be analyzed. For moreinformation please refer to publication E111E.

Indication options

Remote analogue position indication: The Current Position Transmitter (CPT)provides a contact-less internally fed4-20mA analogue signal proportionalto valve position, selectable for minimum signal corresponding tofully closed or fully open positionwith automatic zero and span setting.An externally powered version of theCPT is also available.

Remote analogue torque indication

The Current Torque Transmitter (CTT)provides an internally fed 4-20mAanalogue signal proportional to actuator output torque 0-100%rated.

Extra indication contacts*

The extra indication contacts moduleprovides an additional four change-over contacts, S5, S6, S7 and S8.Each contact is latching, volt free andrated at 5mA to 5A, 120V AC, 30VDC. The extra indication contact functions are independently configurable in the same way as thestandard contacts using the suppliedIQ Setting Tool. The extra indicationcontact functions available are shownbelow:

● Valve position:Fully open, fully closed or intermediate positions (0-99% open)

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● Status:Valve opening, closing, moving (continuous or pulsing signal), local stop selected, local selected, remote selected, open or close interlock active, ESD active

● Valve alarms:Motor tripped on torque in mid travel, motor tripped on torque going open, going closed, pre-set torque exceeded, valve jammed, actuator being operated by handwheel

● Actuator alarms:Lost phase**, customer 24V DC (120V AC) supply lost, battery low, internal failure detected, thermostat tripped

*not available with IQD. **3 phase IQ only.

5.4 Fieldbus system control

Pakscan

An internally mounted Pakscan fieldunit for remote control and statusindication over a fault tolerant two-wire serial link. Loop distances of upto 20 km without repeaters and hostcommunications using Modbus protocol. System variables programmable over the infra-red data link. For more informationplease refer to publication SOOOE.

Modbus

Modbus modules suitable for singleor dual communication highways maybe included in the IQ and IQT actuator to provide fieldbus communication of all the actuatorcontrol functions and feedback data.The fieldbus information is carried onan RS485 data highway and the communications protocol used isModbus RTU. System variables suchas unit address and data baud rateare programmed over the infra-reddata link. For more informationplease refer to Rotork.

Profibus

A Profibus DP interface module isavailable to allow the actuator to beintegrated into a Profibus network.Full compatibility with EN 50170 isprovided and the Profibus networkallows full actuator control and feedback of data to the host. Formore information please refer to publication S113E.

Foundation Fieldbus

An IEC 61158-2 compliant Foundationinterface module allows the actuatorto be connected to a Foundation network. The device has link scheduler capability as well as digital and analogue function block capability. Foundation Fieldbus actuators can communicate directlybetween themselves without theneed of a host supervisory system.For more information please refer to Rotork.

DeviceNet

The ODVA certified DeviceNet interface module, with full status datafeedback and actuator digital andanalogue control, connects directly tothe popular DeviceNet data highway.Data feedback includes both torqueand high accuracy position informationwhile the inbuilt positioner allows forfull modulating control. Up to 63 IQactuators can be connected on a single DeviceNet highway. For furtherinformation refer to publication S116E.

5.5 Protection

The IQ control system incorporatesthe following valve, actuator and control protection:

Obstructed valve (torque trip) protection.

Lost phase protection plus automaticphase rotation correction bySyncrophase.

Jammed valve protection.

Motor thermostat protection.

Internal fault protection - ASTD (auto-matic self test & diagnosis).

Actuator control circuit supplyprotection.

Instantaneous reversal protection.

Control signal fault protection (configurable).

5.6 Actuator set-up

All actuator settings may be configured using the supplied IQSetting Tool over the infra-red interface without the removal of anycovers. Setup can take place withmain power on or power off, duringwhich power is provided by the actuator battery. Each IQ actuatorincludes a comprehensive installationand maintenance manual providinginformation on site commissioningand adjustment. An actuator wiringdiagram is also included. As anoption Rotork IQ-Insight software forPC allows configuration of actuatorsettings. For Bus control systemoptions, tools are available allowingconfiguration testing over the serialinterface as well as by Setting Tool orIQ-Insight software for PC.

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6 Actuator components6.1 Motor

IQ 3 phaseThree phase, Class F, insulated squirrelcage motor of special high torquelow inertia design. 15 minute ratedwith cyclic duration factor of 25% at33% of actuator output rated torquegiving a temperature rise not exceeding that permitted for Class Binsulation at standard nominal voltage. Actuator rated up to 60 startsper hour at a rate not exceeding 600starts per hour. Burnout protection byembedded thermostat, with facilityfor bypassing under emergency shutdown control. For details ofmotor performance and use of uninterruptable power supplies pleaserefer to publication E130E.

Motor options

ModulatingWhen a higher number of starts perhour are required (up to 1200 startsper hour) IQM/IQTM and IQTFM havebeen specifically designed for theseduties. For further details please referto IQM/IQTM publication E410E.

IQS Single Phase

Capacitor start/run squirrel cageinduction motor.

IQD Direct Current

Permanent magnet, DC motor incorporating thermostatic protection.

IQT24V DC permanent magnet, low inertia motor. The IQT motor has aproven 20 year record in valve actuators.

6.2 Power module

IQThe power module incorporates a mechanically and electronicallyinterlocked reversing contactorstarter*. The control supply transformer, fed from two phases ofthe incoming power supply, providesinternal control circuit supplies and anisolated, nominal 24V DC customersupply rated at 5W for actuator fedremote control circuits. The RotorkSyncrophase circuit incorporatesphase rotation correction and lostphase protection.

Option - Control circuit supplyNominal 110V AC supply, rated at20VA (not available with IQD).

*Single Phase and IQM modulating units utilise asolid state motor starter.

IQTThe IQT power module consists of atorroid power transformer with a fastacting micro controller based, intelligent switch mode motor drive.Customer remote control supply is anisolated 24V DC rated at 5W or anoptional nominal 110V AC supplyrated at 20VA.

6.3 Control module

IQ and IQTIncorporating a single integrated circuit, hard-wired logic control forthe actuator together with infra-red(IrDA) interface for external non-intrusive settings and interrogation byIQ-Insight configuration and data logger viewer PC tool. On board datalogger records operational data, valvetorque/position profiles and statisticalinformation, all time and datestamped.

6.4 Torque and position control

IQPosition and torque are adjustable asfollows:

Position setting range:2.5 to 100,000 turns, with a maximum angular resolution to 7.5°of actuator output center column.

IQTTorque setting:40% to 100% rated torque. Torquesensing is derived from drive currentsensing and digital filtering.

Position setting range:Limits are factory set to 90° stop boltpositions (nominal). Limit settingrange: 10° to 1800°. Maximum angular resolution to 0.1°.

The IQT actuator speed range can beconfigured with the IQ Setting Tool.

Output torque for the IQ, is obtained via the direct measurementof wormshaft thrust reaction underload and is independent of voltage, frequency and temperature fluctuations.

For the IQT the output torque is measured using the motor current.Torque off during unseating or duringstarting/reversing in mid travel againsthigh inertia loads can be inhibited.The jammed valve protection circuitde-energizes the motor if no movement occurs after a few secondsfrom receipt of a signal to open orclose.

When power to the actuator is isolated, all settings are retained in anEEPROM. In the event of manualoperation of the valve during isolationor loss of the power supply a batteryprovides power to the internal position-monitoring transmitter toupdate the valve position data in theEEPROM. The battery also drives theLCD display, without backlighting,and the four latching contacts S1-S4while the power to the actuator isnot available. Based on a typicalapplication the minimum battery lifeis 5 years. Infra-red setting is alsoavailable with main power off.

6.5 Conduit entries, terminals and wiring

IQ actuatorsThree threaded conduit entries areprovided tapped: 1 x 11/

2 and 2 x 1”ASA NPT.

Unless otherwise specified, actuatorwill be dispatched with adapters: 1 xM40 and 2 x M25 metric to BS3643,“Ex” certified or as an alternative, 1 x PG29 and 2 x PG16.

It is the responsibility of the installerto ensure the appropriate cable/ conduit adapters and blanking plugsare fitted, in order to maintain hazardous area certification andingress protection levels. Certifiedadapters and blanking plugs are available as optional extras.

If specified with order, a fourth conduit entry can be provided tapped1” ASA NPT with adapter to M25 oras an alternative PG16.

IQT actuatorsStandard cable entries 2 off M25.Additional 2 off M25 entries availableas option. Adaptors for M20, NPT 1”,11/4”, 11/2” option.

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Separately sealed compartment containing segregated metric threadM5 power and M4 control terminals.Terminal screws and washers are supplied with the actuator. The terminal box cover carries a terminalidentification code card. AnInstallation and Maintenance manual(E170E2) and wiring diagram areenclosed with each actuator.

Jig built harnesses of individuallynumbered stranded conductors, tropical grade PVC insulated, connectinternal components to the sealedterminal block. All internal controlconnections to the printed circuitboards are via plugs and sockets.

7 Design specification7.1 Design life

For isolating duty, torque ratings of IQactuators are based on a minimummaintenance free life of 10,000open/close/open cycles with ratedseating torque at stroke end and anaverage of 1/3 rated seating torqueduring stroke. For modulating dutyduring stroke please refer to IQMRange, publication E410E.

Life tests

Standard IQ life test is based on10,000 open/close/open cycles(500,000 output turns) with maximum seating torque at strokeend and an average of 1/3 max. seating torque during stroke.Actuators are stalled against a solidobject 25 times to prove durability.

Standard IQT life test is based on25,000 open/close/open cycles at75% rated torque rising to 100% ateach end of travel.

7.2 Frequency of operation

IQ actuators are suitable for valveduty up to 60 starts per hour.

IQM/IQTM Modulating service: up to1200 starts per hour.

IQ Single Phase: up to 60 starts perhour.

IQDC: up to 60 starts per hour.

7.3 Operating temperature

Actuators are suitable for operationfor ambient temperatures in therange -30°C to +70°C. Please note -Hazardous Area certification definesthe temperature operating range tomaintain certification. Refer to 4.1.

For temperatures outside this rangeplease apply to Rotork.

7.4 Vibration

Standard IQ and IQT Range actuatorsare suitable for applications where vibration severity does not exceed thefollowing applied at the actuatorinterface:

Plant induced: Where the cumulativelevel of all vibration within the frequency range of 10 to 1000Hz isless than 1g rms.

Shock: 5g peak acceleration.

Seismic: Frequency range 1 to 50Hz,2g acceleration if it is to operate during and after the event. 5g if it isonly required to maintain structuralintegrity.

Where excessive plant induced vibration is anticipated, mounting theactuator remote from the valve anddriving via extension shafting incorporating vibration absorbingcouplings may provide a satisfactorysolution. Contact Rotork for furtherdetails.

7.5 Safety integrity

Electromagnetic compatibility directive (EMC)

Actuators conform to the require-ments of the European EconomicCommunity EMC Directive89/336/EEC as amended by92/31/EEC. Contact Rotork for a copyof our Declaration of Conformity.

Low voltage directive (LV)

Actuators conform to the requirements of the EuropeanEconomic Community Low VoltageDirective 73/23/EEC amended by93/68/EEC by the application of EN60204-1 1993. Contact Rotork for acopy of our Declaration of Conformity.

Machinery directive

Actuators follow the provision of theMachinery Directive (89/392/EEC) asamended by 91/368/EEC and93/44/EEC.

The IQ must not be put into serviceuntil the equipment into which it isbeing incorporated has been declaredto be in conformity with the provi-sions of the European CommunityMachinery Directive (89/392/EEC)91/368/EEC and 93/44/EEC. ContactRotork for a copy of our Declarationof Incorporation.

7.6 Noise

Independent tests have shown that at1m generated noise did not exceed61db(A).

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UK head officeRotork Controls Limitedtel: +44 (0)1225 733200fax: +44 (0) 1225 [email protected]

USA head officeRotork Controls Inctel: +1 585 328 1550fax: +1 585 328 [email protected] Rotork Controls Ltd, Bath, UK

Rotork Controls Inc, Rochester, USA

A full listing of our worldwide sales and service network is available on our website atwww.rotork.com

As part of a process of on-going product development, Rotork reserves the right to amend and changespecifications without prior notice. Published data may be subject to change. For the very latest versionrelease, visit our website at www.rotork.com

The name Rotork is a registered trademark. Rotork recognizes all registered trademarks.Published and produced in the UK by Rotork Controls Limited.

Australia tel: +61 353 381566fax: +61 353 [email protected]

Canada tel: +1 403 5699455fax: +1 403 [email protected]

China (Shanghai) tel: +86 21 64785015fax: +86 21 [email protected]

China (Beijing) tel: +86 10 8284 5700fax: +86 10 8284 [email protected]

Francetel: +33 1 43 111550fax: +33 1 48 [email protected]

Germanytel: +49 2103 95876fax: +49 2103 [email protected]

Hong Kong tel: +852 25202390fax: +852 2 [email protected]

India tel: +91 44 6254219fax: +91 44 [email protected]

Indonesia tel: +62 21 580 6764fax: +62 21 581 [email protected]

Italy (Electrics) tel: +39 0245 703300fax: +39 0245 [email protected]

Italy (Fluid System) tel: +39 0583 93061fax: +39 0583 [email protected]

Japan tel: +81 3 5632 2941fax: +81 3 5632 [email protected]

Korea (South) tel: +82 31 2650962fax: +82 31 [email protected]

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Netherlands tel: +31 10 4146911fax: +31 10 [email protected]

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Saudi Arabia tel: +966 3 833 1661fax: +966 3 833 [email protected]

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Thailand tel: +66 2 2727165fax: +66 2 [email protected]

U.K. (Electrics) tel: +44 1225 733 200fax: +44 1225 333 [email protected]

U.K. (Fluid System) tel: +44 113 2057 200fax: +44 113 2363 [email protected]

USA tel: +1 585 3281550fax: +1 585 328 [email protected]

Venezuela tel: +58 212 953 9473fax: +58 212 953 [email protected]

122

Established Leaders in Actuation Technology

Features

• 100%greasefilledforlife andfullysealed

• Comprehensivegearratios combinedwitha selectionofinputgear reducers

• Angularcontactbearings supportingthewormshaft

• Removableand repositionabledrivesleeve

• -40to250°Fstandard temperaturerange

• Adjustabletravelstops +/-5degrees

• Maximumrated outputtorque- 1.47millionin-lbs

• Maximumstemacceptance diameter-12”boredwith ANSIB17.1squarekey

• Maximumbase-FA40

• AboveorBuriedService

Options

• Stemextensions

• Padlockkit

• NAMUR&WestlockPosition indicatormountingkit

• Hightemperature: 0to300°F

• Lowtemperature downto-60°F

• OpenRightService

• 450ft-lbsService

IW Quarter-turn Worm Gear OperatorTheIWAWWAC504wormgearoperatorsaresuitableforbothmotorizedandmanualactuationofAWWAC504butterflyvalves.TheyaredesignedtomeetorexceedallaspectsofAWWAC504specificationandaremanufacturedfromhighqualityandreliablematerials.Overloadandlifetestsreportsareavailableuponrequest.AllRotorkGearsactuatorsaremadetoISO9001standards.

C504 Quarter-turn Worm Gear Operator

IW SeriesAWWA

123

Formerly RGi112E. As part of a process of on-going product development, Rotork reserves the right to amend and change specifications without prior notice. Published data may be subject to change.

For the very latest version release, visit our website at www.rotork.com.

The name Rotork is a registered trademark. Rotork recognizes all registered trademarks. Published and produced in the UK by Rotork Controls Limited. POWSH0810

A full listing of our worldwide sales and service network is available on our website at

www.rotork.com

Rotork Gears BVNijverheidstraat 257581 PV LosserP.O. Box 98 7580 AB LosserThe Netherlands

tel: +31 (0)53-5388677fax: +31 (0)53-5383939email: [email protected]

Rotork Gears UK Regina HouseRing RoadBramley, LeedsWest Yorkshire LS13 4ETEngland

tel: +44 (0)113 2057276fax: +44 (0)113 2563556email: [email protected]

Rotork Gears Americas1811 BrittmooreHoustonTexas 77043USA

tel: +1 713 983 7381fax: +1 713 856 8022email: [email protected]

Rotork Gears S.R.L.via Olona, 65/6720015 Parabiago (MI)Italy

tel: +39 0331 552128fax: +39 0331 553147email: [email protected]

Rotork ValvekitsBrookside Way,Nunn Park,Huthwaite,Nottinghamshire, NG17 2NLEngland

tel: +44 (0)1623 440211fax: +44 (0)1623 440214email: [email protected]

Rotork Gears India 165/166, Bommasandra,Jigani Link Road,Kiadb Industrial Area,Anekal Thaluk, Jigani Hobli,Bangalore 562106

tel: +91 80 3098 1600fax: +91 80 3098 1610email: [email protected]

PUB028-003-00 Issue 08/10

Rotork Gears ShanghaiNo. 260 Lian Cao RoadXin Mei Urban Industrial ParkMin Hang DistrictShang Hai 201108China

tel: 0086-21-64348388fax: 0086-21-64348366email: [email protected]

Handwheel Selection Chart

C504 Quarter-turn Worm Gear Operator

IW SeriesAWWA

Material Specification

Component Material Specification / Notes

Gearcase DuctileIron ASTMA53665-45-12 Baseplate CastIron ASTMA4835B/40B WormShaft Steel AISI4340 Quadrant ManganeseBronze ASTMB584C86300 PositionIndicator Steel AISI1023 Drivesleeve Steel AISI1023or1040or1055 Bearings AngularContact O-Ringseals Nitrile Fasteners 316SS Grease RenolitCL-X2 InputShaft 431SS

40

36

32

28

24

20

16

1212

88

6040 80 120RIM Effort in lb

Example how to use this Chart:1 Get the input torque required Output Required Input Torque = M.A.2 Define Maximum allowable RIM effort (standard is 80lb)3 Select Handwheel diameter

Han

dw

hee

l Dia

met

er in

inch

es

Input Torque in Ft-lb10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

ØH K

‘N’ SPOKES

‘F’ Type handwheel

Type ØH K N F200 8 2.97 3 F300 12 3.96 3 F400 16 3.96 4 F500 20 3.96 4 F600 24 3.96 4 F700 28 3.96 6 F800 32 3.96 6 F900 36 3.96 6 F1000 40 3.96 6 F1100 44 3.96 6 F1200 48 3.96 8

Dimensions

124

OSHA Lock Out/Tag OutOSHA requires the use of Lock Out/Tag Out devices whenever service or maintenance is being performed in proximity to a machine in order to prevent injury potentially caused by unexpected start up of machinery. ABB’s enclosed disconnects are equipped with selector or pistol grip handles which are padlockable and defeatable with clear position indication.

Motor DisconnectsABB’s UL 508 listed disconnect switches are designed to meet National Electric Code, Article 430-102, requiring a disconnect means, located within sight from the motor location and the machinery location.

The Nema 4X rated switches from ABBIdeal for Food and Beverage Processing machinery, ABB’s Nema 4X rated enclosed disconnect switches provide exceptional durability. These switches offer protection against corrosion, windblown dust and rain, splashing water, hose-directed water and damage from external ice

formation for indoor or outdoor applications. ABB’s Nema 4X Enclosed Switch Portfolio includes both stainless steel and plastic options.

Enclo

sed S

witc

hes



Food & beverage processing

Disconnect Switches are

typically used in Food

and Beverage Processing

applications as a main

disconnecting means;

OSHA Lock Out/Tag Out

devices to isolate a load

for maintenance, service

or repair; or as the NEC

required motor disconnect

upstream from the motor.

125

126

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RG-IW-002Issue 07/10

INSTRUCTIONS FOR USE

WORM GEAR OPERATORS

Worm Range Specification: Installation, Operating and Maintenance Instructions: Assembly and Dismantling Instructions: Spare Parts List and Recommended 5 Years Holding List:

Rotork Gears, Regina House, Bramley, Leeds, LS13 4ET, England.

129

C.F. 07.07.06 issue 3F:\Exeeco\GBOX\ENGINEER\ATEX\Instructions\UPDATE-08-06\Worm Specificationr3.doc

ROTORK GEARS WORM RANGE SPECIFICATION

Component Material Specification

Gearcase Cast Iron or SG Iron, optional Carbon Steel, Stainless Steel.

Baseplate Cast iron as standard, optional SG Iron, Carbon Steel or Stainless Steel.

Input Housing Cast Iron as standard, optional SG Iron, Carbon Steel or Stainless Steel.

End cap Cast Iron or Carbon Steel, optional SG Iron, Stainless Steel.

Worm Gear SG Iron or Aluminium Bronze.

Worm Shaft Carbon Steel as standard, optional Stainless Steel.

Indicator plate Carbon steel, optional Stainless Steel.

Screws High Tensile Steel Metric Standard to BS3692 & 4168 as standard, optional Stainless Steel.

Bearings Angular contact bearings.

Output Sleeve Steel or Cast Iron, optional Stainless Steel or Aluminium Bronze.

Lubricant CL-X2 (Standard) max temp 120°C: Ignition temperature > 250°CLX-EP2 (High temp) max temp 160°C: Ignition temperature > 250°CNO-TOX EP2 (Food) max temp 204°C: Ignition temperature > 250°CMO2 (Graphite) max temp 120°C: Flash point > 200°CG110 (Nuclear) max temp 150°C: Flash point > 200°CG130 (Nuclear) max temp 150°C: Flash point > 200°CLST 0 (Oil for MTW,MOW) max temp 135°C: Ignition temperature > 250°CEPLITH 00 (MTW) max temp 120°C: Ignition temperature > 250°C

Seals Nitrile (Standard) max temp 150°C: Ignition temperature > 300°CViton (High temp/ Nuclear) max temp 200°C: Ignition temperature > 315°CFluorosilicone (Low temp) max temp 225°C: Ignition temperature > 300°CSilicone sealant max temp 200°C: Ignition temperature > 450°C

Gearbox Detail Gearbox Specification

Gearbox design Life IW: 10000 cycles at one third maximum torqueMTW: 10000 output revolutions at one third maximum torqueMOW: 2 years or 17,520 hours continuous operation

Gears Designed basically to BS721

Gearbox type Indicated on the nameplate

Gearbox ratio Indicated on the nameplate

Maximum output torque Indicated in the Rotork Gears catalogue

Gearbox duty specification Indicated on the nameplate

Nameplate Explosion Marking and Category According to 94/9/EC and indicated on the nameplate

Maximum speed for the input shaft 350 rpm. (IW and MOW must have input reducers fitted and combined ratiosgreater than 720:1 to operate at this speed)

Maximum bending moment on the input flange F10: 200NmF14: 340NmF16: 520NmF25: 1450NmF30: 1580Nm

Maximum operating temperature Indicated on the nameplate

Gearbox weight Indicated on the nameplate

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Manganese Bronze

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N/A

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N/A

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(IW8, used on 54" Valves)

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(IW5, used on 14", 16", 18", 20" Valves)

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C.F. 27.07.10 issue 2 F:\Exeeco\GBOX\ENGINEER\ATEX\Instructions\Worm\Installation Instructions For WormR2.doc

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS FOR EXEECO WORM GEAR OPERATORS

The Rotork Gears Worm Range Specification sheets indicate the materials of construction and information for putting the equipment into service. The gearbox is marked according to 94/9/EC with the temperature class and explosion group on the equipment and this shall be observed when installing and operating the equipment. The user alone is responsible for the appropriate use of the gearbox in consideration of the basic conditions existing at the plant. This range of gearboxes is supplied to suit the order requirements but, unless specifically requested at the ordering stage, the output sleeve will be supplied blank and must be machined to suit the equipment to be operated. IW12 & IW13 gearboxes do not have removable output sleeves and are supplied machined to the customer’s specification. The sleeve can be easily removed from the top of the gearbox by first removing the indicator plate retaining bolts. These bolts are either serrated under head or are fitted with serrated washers. When refitting the bolts, they must be tightened to the correct torque figures as shown under the indicator plate. The recommended tightening torque of screws is also shown in the table below. NOTES FOR MOUNTING TO THE VALVE The following are basic instructions for mounting the gearbox. For detailed information see the Gearbox Installation Manual “RG-INSTALL” and “RG-IW-OS1” 1. The valve spindle must be greased before assembly of the gearbox to the valve. 2. Flanges to be sealed on assembly with silicone sealant. 3. It is essential that the gearbox baseplate is flush with the valve bonnet flange before the mounting screws are tightened. If the gearbox has been supplied with a handwheel, it is recommended that this be fitted to the gearbox before mounting on the valve. This will make it easier to rotate the gearing to pick up the start of a thread or key location. On a keyed valve shaft, once the key and keyway are lined up, the gearbox can be lowered onto the mounting flange and bolted down. On a screwed valve shaft, rotating the handwheel will cause the gearbox to screw itself down the spindle. Once in the correct position it can be bolted down. When bolting the valve to the gearbox we recommend using at least grade 8.8 fasteners, and these MUST be torque tightened dependent upon the grade and size used. If an electric actuator is fitted to the gearbox, a suitable input adaptor will have been supplied. After mounting the actuator to the gearbox, the limit and torque switch settings must be made in accordance with the manufacturer’s instructions. The maximum permitted bending moment on the input adaptor of the gearbox is indicated on the gearbox specification sheet. HANDLING Combined valve, actuator and gearbox must NOT be slung from the gearbox. MAINTENANCE All gear cavities are lubricated and sealed for life and the type of grease and seals used within the gearbox is indicated on the nameplate and shown in the material specification. The required maintenance intervals depend on the respective application and will therefore have to be determined by the user dependent on the conditions of use. Annual inspection of the gearbox is recommended, but under normal operating conditions no maintenance is required for the gearbox, but should the valve be taken out of service for overhaul, the gearbox baseplate may be removed and the grease renewed. The baseplate must be sealed using silicone sealant on re-assembly, unless fitted with an O ring. Below is a table for the recommended tightening of screws. HEXAGON HEAD GRADE 8.8 HEXAGON HEAD GRADE 8.8

WITH NORDLOCK WASHER SOCKET HEAD GRADE 12.9 SOCKET HEAD GRADE 12.9

WITH NORDLOCK WASHER DURLOK GRADE 12.9

SCREW GRADE 12 NUT SCREW SIZE











M4 2 2 3 2 4 3 5 4 M5 5 4 6 4 8 6 10 7 11 8 M6 9 6 10 8 14 11 17 13 19 14 M8 21 15 25 18 35 26 42 31 45 33 M10 41 30 49 36 69 51 83 61 86 64 M12 71 53 86 63 121 89 145 107 152 112 M16 177 131 213 157 299 221 359 265 372 274 M20 346 255 415 306 584 431 701 517 717 529 M24 598 441 718 529 1009 744 1211 893 M30 2006 1480 M36 3508 2587

Note: Once fully torque tightened Durlok fasteners must not be re used on

Nuclear gearboxes

Copy of QC 40-2 NB. All internal cavities within the gearbox must be packed with grease. SPARES Spare parts must be selected from the spare parts lists and a recommended spares holding for 5 years is shown on the spare parts list.

131


PROCEDURE FOR DISMANTLING / RE-ASSEMBLY OF WORM GEAR OPERATORS

1. PURPOSE: To provide dismantling / re-assembly instructions.

2. SCOPE: Rotork Gears range of worm gearboxes

3. DEFINITION: Sequence of instructions to dismantle and re-assemble Rotork Gears worm gearboxes.

4. PROCEDURE: Refer to spare parts list for item numbers. For additional information see Documentation.

4.1 Dismantling

4.1.1 If the worm gearbox is fitted with an input reducer see the dismantling instructions for the input reducer to first remove the input reducer.

4.1.2 For output sleeve with o rings, to prevent damage to the o rings (28), slightly loosen ALL the socket head cap screws/Durlok (11) before fully removing the screws.

4.1.3 Fully remove the output sleeve screws (11) from indicator plate (8). 4.1.4 Remove the indicator plate (8) and o rings (28). 4.1.5 Remove the output sleeve (5) where applicable. 4.1.6 Remove the key (20) from the worm shaft (4). 4.1.7 Remove the screwed fasteners (17), which secure the input housing (7) to the gearcase (1). 4.1.8 Remove the input housing from the gearcase. 4.1.9 The worm shaft can sometimes be removed at this stage by unscrewing the worm from the wormwheel

(3). 4.1.10 Remove the screwed fasteners (27) that secure the baseplate (2) to the gearcase. 4.1.11 Remove the baseplate from the gearcase. 4.1.12 Remove the wormwheel (3) from the gearcase. 4.1.13 Remove the screwed fasteners (18) that secure the end cap (6) to the gearcase and remove the end cap. 4.1.14 If the worm shaft was not removed in 4.1.6 then remove the worm shaft complete with the angular

contact bearings (9) and shim (10) where applicable. 4.1.15 Remove bearings from the input housing, end cap or gearcase. 4.1.16 Loosen the lock nuts (16) and remove the stop bolts (15) from the gearcase where applicable.

4.2 Re-assembly

4.2.1 Ensure all parts are free from dirt and bruising 4.2.2 On re assembly, all moving parts should be lightly lubricated with grease before refitting. 4.2.3 Ft the ‘o’ ring (14) to the gearcase. 4.2.4 Fit the bearing(s) in the end cap or within the gearcase, making sure that the bearing is orientated

correctly and packed with grease. 4.2.5 Fit the ‘o’ ring or apply sealant (25) to the end cap and secure to the gearcase with the screwed

fasteners. 4.2.6 Re-fit the worm shaft into the gearcase and locate with the bearing contained by the end cap. 4.2.7 Fit the bearing(s) in the input housing or within the gearcase, making sure that the bearing is orientated

correctly and packed with grease. 4.2.8 Fit the ‘o’ ring (12) to the input housing. 4.2.9 Fit the ‘o’ ring or apply sealant (25) to the input housing and secure to the gearcase with the screwed

fasteners. 4.2.10 Grease the worm shaft and gearcase before refitting the worm wheel. 4.2.11 Re-fit the wormwheel, locating the worm wheel spigot into the bore of the gearcase and ensuring the

gear teeth mesh with the worm shaft. 4.2.12 Fit the lock nuts to the stop bolts and apply sealant to the stop bolts and refit into the gearcase where

applicable. Do not tighten. 4.2.13 Re-pack the gearcase with grease. 4.2.14 Fit the ‘o’ ring or apply sealant (26) to the baseplate and re-fit the baseplate into the gearcase. 4.2.15 Re-secure the gearcase to the baseplate using the existing screws (27) using a diagonal tightening

movement. 4.2.16 Fit the ‘o ring (13) into the baseplate. 4.2.17 Fit the output sleeve into the gearcase where applicable. 4.2.18 If o rings (28) are used with the output sleeve, position the o rings in the countersink holes of the

output sleeve.

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4.2.19 Fit the indicator plate. 4.2.20 Loosely fit all of the existing cap screws or Durlok bolts to prevent trapping the o rings (28). Once all

screws have been loosely fit, then torque tighten all screws sequentially. 4.2.21 Re-fit the key to the worm shaft and test the gearbox for free rotation. 4.2.22 For gearboxes with stop bolts rotate the output sleeve to the required position. Adjust the stop bolt and

lock with the lock nut. Repeat for the remaining stop bolt.

5. DOCUMENTATION

Spare parts list for range of worm gear actuators: IWSPARES. Torque tightening figures. Document No QC 40-2 Procedure for replacing old style output sleeves IW-OS1 Gearbox Installation Manual RG-INSTALL

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PART SECTION

SECTION


15

2716

11

1928

13

14

26

58

74

2 1

3


17

20

12

18 925 9

6

10

22

21

23

22

21

11

828

204

1

14

518

2510

9

925

7 12

17

19

23

15

16

313

262

27

6


INDICATOR PLATE




134

PROCEDURE FOR ATTACHING NAMUR MOUNTING KITS TO IW GEARBOXES(THIS PROCEDURE APPLIES TO IW3, IW4, IW5, IW6, IW7, IW8, IW9, IW10, IW11, IW12 AND IW13)

Rotork GearsRegina HouseRing RoadBramleyLeedsEngland LS13 4ET Ref: CA15 (Namur Mounting Kit Instructions)

1. See Fig. 12. Locate the gearbox either in the fully open or fully closed position. To prevent misalignment, the gearbox input shaft should not be moved again until the mounting kit has been fully fitted.3. Remove the output sleeve screws (item 1) and the washers (item 2) from the cover plate (item 3). Do not discard these screws and washers as they will be used for the mounting kit.

4. See Fig. 25. Fit the drill jig (item 4) to the output sleeve (item 5). Note that the dowels in the drill jig will locate with the holes in the output sleeve.6. Use two washers and two output sleeve screws to fix the jig to the output sleeve.7. Line up a Ø4.2 drill with the holes in the drill jig and drill 10mm deep into the gearcase. Note that some holes may break through.8. Remove the two screws, two washers and drill jig from the output sleeve.9. Use a M5 Tap and thread the four drill holes 8mm deep.10. Carefully remove all swarf. 11. See Fig 3.

12. Fit the new switchplate cover (item 6) to the output sleeve.13. Fully torque tighten the output sleeve screws, with washers, to the torque indicated on the switchplate cover.14. See Fig 4.

Fig.1

Fig.2

Fig. 3 Fig. 4

1

2

3

1

24

5

6

2

1

7

12

11 10

9

8

15. Screw the shoulder screws (item 7) into the gearcase.16. Screw the Namur stud (item 8) into the nut on the switchplate cover. This is adjustable and can be locked with the locking nut (item 9).17. Use the fixing screws (item 12) and washers (item 11) to fasten the mounting plate (item 10).18. The mounting kit is fully fitted and a switchbox can now be mounted to the gearbox.

135

136

137

138

139

140

141

142

143

144

145

146

IQ Recommended Spare Parts

The IQ series of actuator is designed to be maintenance free for its lifetime. Rotork recommends no spare parts are necessary.

147




PART SECTION

SECTION


15

2716

11

1928

13

14

26

58

74

2 1

3


17

20

12

18 925 9

6

10

22

21

23

22

21

11

828

204

1

14

518

2510

9

925

7 12

17

19

23

15

16

313

262

27

6


INDICATOR PLATE




148

SAFETY PRECAUTIONS

Gearbox may present an unbalanced load.

With respect to handwheel operation of Rotork gearboxes, under no circumstances should any additional lever device such as a wheel-key or wrench be applied to the handwheel in order to develop more force when closing or opening the valve as this may cause damage to the valve and/or gearbox or may cause the valve to become stuck in the seated/backseated position.

Keep clear of the handwheel when engaging hand operation. Actuators driving valves via extension shafts may be subject to retained shaft torsion which can cause the handwheel to rotate when hand operation is engaged.

The actuator should be fully supported until full valve shaft engagement is achieved and the actuator is secured to the valve flange.

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

149

Date post:	16-Jan-2016
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“OPERATIONS AND MAINTENANCE INSTRUCTIONS”

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