You are on page 1of 151

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
Contractors 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

TABLE OF CONTENTS
Document No.

J49192
J49181
J49201
J49186
J49191
PUB-IW5R WL
B4342201-04
IW5A672
IW8A502
DOC1522
DOC755-2

43824-10

3010-000-08
RWS300
B43422-1

DP00038
DP00091

E110E

RG-IW-002
CA15

Title Page
Table of Contents
Data Sheets
Bid item 1 - Electric Actuator for use with 54" ANSI Butterfly Valve
Bid item 2 - Manual Gear for use with 20" ANSI Butterfly Valve
Bid item 3 - Manual Gear for use with 18" ANSI Butterfly Valve
Bid item 4 - Manual Gear for use with 16" ANSI Butterfly Valve
Bid item 5 - Manual Gear for use with 14" ANSI Butterfly Valve
Bid item 7 - Spare Parts for Manual Actuator
- Spare Parts for Electric Motor & Gearbox
Drawings
54" ANSI Butterfly Valve with Electric Actuator
18 & 20" ANSI Butterfly Valve with Manual Actuator
16 ANSI Butterfly Valve with Manual Actuator
14 ANSI Butterfly Valve with Manual Actuator
Connecting Parts FUW BHP Butterfly Valves
Rotork IW5R Manual Actuator Outline
Rotork IQ12 Electric actuator with IW8 Worm Gear
Rotork IW5R Manual Actuator Assembly
Rotork IW5R Manual Actuator Assembly
IQ Terminal Block
Rotork IQ Electric Actuator Assembly
British Standards Cross Referenced to ASTM
Lubrication Drawing
Nameplate Drawing
Disconnect Drawing
Actuator Wiring Diagram
Remote Wiring Diagram
Motor Data
Motor Data Sheet
Electrical Motor Data
Relay Data
Operations & Maintenance Manuals
Rotork Gearboxes
Rotork IQ Actuators
Additional Data
Catalog Cuts
IQ Brochure
IW Brochure
Disconnect Brochure
Disconnect Cut Sheet
Switch Cut Sheet
Worm Gear Instructions
Limit Switch Mounting Details
MSDS Sheets
IQ Actuator Recommended Spare Parts
IW Gearbox Recommended Spare Parts
Safety Precautions

Page
1
2
3
7
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28
29
30
31
43

91
123
125
126
127
129
135
136
147
148
149

Submittal Data Sheet


Date: 10/05/11
PACIFIC INFRASTRUCTURE CORPORATION
2134-C RHEEM DRIVE
PLEASANTON, CA 94588

P.O. 1073-5693
FACTORY ORDER NO 770548
FACTORY SALES ORDER NO 611813

Citrus Pump Station, Crafton Hills Pump Station, and Cherry Valley Pump Station East Branch Extension Phase II
Fact.
ITEM
1

BID
ITEM
1

QTY
2

DESCRIPTION
PART NO. 9612529
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
2

BID
ITEM
1

QTY
2

DESCRIPTION
DISCONNECT SWITCH

ROTORK DISCONNECT SWITCH


UNFUSED
NEMA 4X
FIBERGLASS
16 AMP

TAGS
CS-BFV-9
CS-BFV-10
WEIGHT (LBS)
MOTOR
WORM GEAR
TOTAL

70
489
559

PART NO. 1394665

Submittal Data Sheet


Date: 10/05/11
PACIFIC INFRASTRUCTURE CORPORATION
2134-C RHEEM DRIVE
PLEASANTON, CA 94588

P.O. 1073-5693
FACTORY ORDER NO 770266
FACTORY SALES ORDER NO 611812

Citrus Pump Station, Crafton Hills Pump Station, and Cherry Valley Pump Station East Branch Extension Phase II
Fact.
ITEM
1

BID
ITEM
2

QTY
7

DESCRIPTION
PART NO. 9612523
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

Submittal Data Sheet


Date: 10/05/11
PACIFIC INFRASTRUCTURE CORPORATION
2134-C RHEEM DRIVE
PLEASANTON, CA 94588

P.O. 1073-5693
FACTORY ORDER NO 770266
FACTORY SALES ORDER NO 611812

Citrus Pump Station, Crafton Hills Pump Station, and Cherry Valley Pump Station East Branch Extension Phase II
Fact.
ITEM
2

BID
ITEM
3

QTY
2

DESCRIPTION
PART NO. 9612524
ROTORK IW5 MANUAL GEAR OPERATOR
FOR USE WITH 18 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-7
CS-BFV-8
WEIGHT (LBS)
WORM GEAR

128

Submittal Data Sheet


Date: 10/05/11
PACIFIC INFRASTRUCTURE CORPORATION
2134-C RHEEM DRIVE
PLEASANTON, CA 94588

P.O. 1073-5693
FACTORY ORDER NO 770266
FACTORY SALES ORDER NO 611812

Citrus Pump Station, Crafton Hills Pump Station, and Cherry Valley Pump Station East Branch Extension Phase II
Fact.
ITEM
3

BID
ITEM
4

QTY
1

DESCRIPTION
PART NO. 9612525
ROTORK IW5 MANUAL GEAR OPERATOR
FOR USE WITH 16 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
CV-BFV-21
WEIGHT (LBS)
WORM GEAR

128

Submittal Data Sheet


Date: 10/05/11
PACIFIC INFRASTRUCTURE CORPORATION
2134-C RHEEM DRIVE
PLEASANTON, CA 94588

P.O. 1073-5693
FACTORY ORDER NO 770266
FACTORY SALES ORDER NO 611812

Citrus Pump Station, Crafton Hills Pump Station, and Cherry Valley Pump Station East Branch Extension Phase II
Fact.
ITEM
4

BID
ITEM
5

QTY
2

DESCRIPTION
PART NO. 9612526
ROTORK IW5 MANUAL GEAR OPERATOR
FOR USE WITH 14 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-1
CS-BFV-2
WEIGHT (LBS)
WORM GEAR

128

Submittal Data Sheet


Date: 10/05/11
PACIFIC INFRASTRUCTURE CORPORATION
2134-C RHEEM DRIVE
PLEASANTON, CA 94588

P.O. 1073-5693
FACTORY ORDER NO 770266
FACTORY SALES ORDER NO 611812

Citrus Pump Station, Crafton Hills Pump Station, and Cherry Valley Pump Station East Branch Extension Phase II
Fact.
ITEM
6

BID
ITEM
7
PART NO.

QTY
12

DESCRIPTION
PART NO. 1394674
SPARE PARTS SET FOR ROTORK IW5A672 WORM GEAR ACTUATORS
DESCRIPTION

QUANTITY

SPARE PARTS FOR ROTORK IW5A672 WORM GEARS SEE DRAWING NO. IW5A672
0096-24N
O-RING
8
0245-30N
O-RING
1
0295-30N
O-RING
1
0595-30N
O-RING
2
0795-30N
O-RING
1
0995-30N
O-RING
1
1395-30N
O-RING
1
2395-30N
O-RING
1
HSM10X25SS-P
HEXAGON SET SCREW
8
HSM16X35SS
HEXAGON SET SCREW
4
HSM20X80EHTZP
HEXAGON SET SCREW
2
NL10
NORDLOCK WASHER
8
NM20ZP
HEX NUT
2
SCM10X25SS17/4PH
SOCKET HEAD CAP SCREW
12
SCM10X45ZP
SOCKET HEAD CAP SCREW
8
SEALANT
SILICONE SEALANT
0.10 L

NOTE: NO SPECIAL TOOLS REQUIRED

ITEM

1
2
3
4
5
6
7
8
14
15
16
32
33
35
36
37

Submittal Data Sheet


Date: 10/05/11
PACIFIC INFRASTRUCTURE CORPORATION
2134-C RHEEM DRIVE
PLEASANTON, CA 94588

P.O. 1073-5693
FACTORY ORDER NO 770548
FACTORY SALES ORDER NO 611813

Citrus Pump Station, Crafton Hills Pump Station, and Cherry Valley Pump Station East Branch Extension Phase II
Fact.
ITEM
3

BID
ITEM
7
PART NO.

71-130
71-659
71-656
Mod. 11A
Mod. 1H
Mod. 6G
Mod. 2C
Mod. 6D

QTY
2

DESCRIPTION
PART NO. 1394666
SPARE PARTS SET FOR ROTORK ELECTRIC ACTUATOR
DESCRIPTION

QUANTITY

SPARES FOR ROTORK IQ12FA10 B4


ELECTRIC ACTUATOR SEE DRAWING NO. DOC755
Fuses
Fuses
Fuses
Maintenance Kit
Resolver PCB
Main PCB
(B4) - Drive Bushing
Contactor Assembly

ITEM

2
2
2
1
1
1
1
1

N/A
N/A
N/A
N/A
69
82
56
78

8
1
1
2
1
1
1
1
8
8
1
2
4
16
8
8
2
0.10L

1
2
3
4
5
6
7
8
14
15
16
32
33
35
36
42
43
44

SPARE PARTS FOR ROTORK IQ8R720


WORM GEAR SEE DRAWING IW8A502R
0195-30N
0395-30N
0495-30N
0845-30N
0995-30N
1895-30N
1943-57N
2593-57N
HSM16X35SS-P
HSM20X100EHTZP
IBIB63
NNM30ZP-T
NL12SS
NL16SS
NL20SS
SCM20X80ZP
SCM30X100SPFT
SILICON

O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
HEXAGON SET SCREW
HEXAGON HEAD SET SCREW
NAMEPLATE
LOCK NUT
NORDLOCK WASHER
NORDLOCK WASHER
NORDLOCK WASHER
SOCKET HEAD CAP SCREW
SOCKET HEAD CAP SCREW
SILICON SEALANT
NOTE: NO SPECIAL TOOLS REQUIRED

10

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

11

TAG: CV-BFV-21

12

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

13

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

14

51
2.02"

64
2.50"
CRS

170
6.70"

137
5.40"

O30 [1.18"]
INPUT SHAFT
FA14
INPUT

178
7.01"

136
5.35"

190
7.48"

50
1.97"

143
5.64"

28
11. 5
22"

65
2.57"

120
4.72"

112
4.42"
MAX STEM ENTRY
WESTLOCK 2007X

FA14 OUTPUT
4 HOLES X 5/8-11UNC
EQUALLY SPACED AS
SHOWN ON O5.50" P.C.

MAX BORE
O76 [3"]

176
6.94"
335
13.20"
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

2" SQUARE NUT


(WELDED TO HUB)

O24" HANDWHEEL

IW5R 120:1 FA14 INPUT, FA14 OUTPUT, 24" HANDWHEEL WITH 2" NUT
WITH WESTLOCK 2007X SWITCHBOX
DETAILS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE

FOR UP TO DATE DETAILS VISIT www.rotork.com

15

DRAWING No.
DRAWN

PUB-IW5R WL
RJONES

DATE

08/03/2011

ISSUE

Rotork Gears Americas


1811 Brittmoore
Houston
Texas
77043
U.S.A.

CS-BFV-9, CS-BFV-10

16

IW5A672
ISSUE

ALTERATIONS

ORIGINAL ISSUE

ITEM

PART NUMBER

DESCRIPTION

DO NOT SCALE

32
24
MATERIAL

QTY

0096-24N

O RING

NITRILE

0245-30N

O-RING

NITRILE

0295-30N

O-RING

NITRILE

0595-30N

O-RING

NITRILE

0795-30N

O-RING

NITRILE

0995-30N

O-RING

NITRILE

1395-30N

O-RING

NITRILE

2395-30N

O-RING

NITRILE

6005

DEEP GROOVE BALL BEARING

STEEL

10

6206

DEEP GROOVE BALL BEARING

STEEL

11

7205B

ANGULAR CONTACT BALL BEARING

STEEL

12*

CLX2

GREASE

RENOLIT CLX2

13

FL17

INPUT FLANGE

SG IRON BS EN 1563 EN-GJS-450-10

14

HSM10X25SS-P

HEXAGON SET SCREW

STAINLESS STEEL GRADE A4/80

15

HSM16X35SS

HEXAGON SET SCREW

STAINLESS STEEL GRADE A4/80

16

HSM20X80EHTZP

HEXAGON SET SCREW SCREW

STEEL 12.9 STRENGTH GRADE

17

IB1B64

NAMEPLATE

ALUMINIUM TO BS1470 GRADE H4A

18

IR1A129

INPUT SHAFT & GEAR 3:1

STAINLESS STEEL BS970 431S29T

19

IR1B12/2

OUTPUT GEAR

STEEL BS970 605M36T

20

IR1D05

GEARCASE

CAST IRON TO BS 1452 GRADE 250

21

IW3A188

LABEL - SHCS/NORDLOCK WASHER

SELF ADHESIVE PAPER

22

IW5A546

FA14 INPUT FLANGE

SG IRON BS EN 1563 EN-GJS-400-15

23

IW5A565

OUTPUT SLEEVE

STEEL TO BS 970 GRADE 080M40 (EN8) or


GB699-88 GRADE 45

24

IW5A567

INDICATOR PLATE

MILD STEEL

25

IW5A581/1/2

WORM QUADRANT

BS1400 HTB3 / BS EN 1982 CC7625/ASTM


B584 UNS C86300 (MANGANESE BRONZE)

26

IW5A665

GEARCASE

SG IRON BS EN 1563 EN-GJS-450-10

27

IW5C102/2

WORM SHAFT LH

STEEL BS970 605M36T

28

IW5C12/1

END CAP

CAST IRON TO BS1452 GRADE 17 OR STEEL


TO BS970 GRADE 070M20

29

IW5D06/3

BASEPLATE

CAST IRON BS EN 1561 EN-GJL-250

30

K8X7X40

KEY 8 X 7 X 40

KEY STEEL TO BS 4325 PART 1

31

K8X7X40SS

KEY 8X7X40 SS

STAINLESS STEEL GRADE A4

32

NL10

NORDLOCK WASHER

STEEL ZINC PLATED

33

NM20ZP

HEX NUT

STEEL BS3692 GRADE 8 (ZINC PLATED)

34*

PA24

PAINT PE3

PRIMER PAINT PE3

35

SCM10X25SS17/4PH

SS SOCKET HEAD CAP SCREW 17/4PH

STAINLESS STEEL TO BS970 GRADE 17/4 PH

12

36

SCM10X45ZP

SOCKET HEAD CAP SCREW

STEEL GRADE 12.9 ZINC PLATED

37*

SEALANT

SILICONE SEALANT

SILICONE

38

T0A11

SPACER

STEEL BS970 070M20

REGINA HOUSE
RING ROAD
BRAMLEY
LEEDS
WEST YORKSHIRE

ISOMETRIC

36

ROTORK GEARS

EXEECO LTD C 2010

THIRD ANGLE PROJECTION

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

2
1.2 kg

0.20 L

35

21
23
4

11
29.98

O 29.95
1.180"

1.179"

28

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

15

26
17

O 140.00
5.512" PC

11

95.32

O 95.27
3.753"

22

3.751"
SPIGOT RECESS

2
9
33

16

19

27

SCRAP VIEW INPUT


1:5

31

30
25

35

38

8
35

20

18
10

29

10
5

0.10 L

13

14

NOTES:
1. ALL DIMENSIONS IN MM

MATERIAL:-

WEIGHT: 53.92 kg

DRAWN:-

J. PRIESTLEY 07/04/2010
C.F. 09/04/2010

CHECKED:-

SCALE

1 : 10 (A3)

AWWA C504-06-IW5

PROJECT:- 2010 AWWA C504-06 120:1 IW5ABOVE GROUND SERVICE GEARBOX.

17

HEAT
TREATMENT

PROTECTIVE
TREATMENT

SUITABLY PROTECT
FOR STORAGE

IW5A672

IW8A502
ISSUE

EXEECO LTD C 2010

THIRD ANGLE PROJECTION

ALTERATIONS

42

ORIGINAL ISSUE

TAG: CS-BFV-9, CS-BFV-10


35

28
REF

DESCRIPTION

MATERIAL

QTY

O RING

NITRILE

O-RING

NITRILE

O-RING

NITRILE

O-RING

NITRILE

O-RING

NITRILE

O-RING

NITRILE

O-RING

NITRILE

O-RING

NITRILE

DEEP GROOVE BALL BEARING

STEEL

10

DEEP GROOVE BALL BEARING

STEEL

11

ANGULAR CONTACT BEARING - WESTERN

STEEL

12*

GREASE

RENOLIT CLX2

13

INPUT FLANGE

CAST IRON BS EN 1561 EN-GJL-250

14

HEXAGON SET SCREW

STAINLESS STEELGRADE A4/80

15

HEXAGON HEAD SET SCREW

STAINLESS STEELGRADE A4/80

16

NAMEPLATE

STAINLESS STEEL304

17

SPACER

MILD STEEL TUBE 2.25" OD x 14 SWG

18

INPUT SHAFT& GEAR 12:1

STAINLESS STEELBS970 431S29T

19

OUTPUT GEAR

SG IRON BS EN 1563 EN-GJS-700-2

20

GEARCASE

CAST IRON TOBS1452 GRADE 250

21

LABEL - SHCS/NORDLOCK WASHER

SELF ADHESIVE PAPER

22

BASEPLATE

CAST IRON BS EN 1561 EN-GJL-250 (CASTING


E-IW8A199)

23

AWWA WORM SHAFT

STEEL BS970 817M40V

24

GEARCASE

SG IRON BS EN 1563 EN-GJS-400-15

25

END CAP

SG IRON BS EN 1563 EN-GJS-400-15

26

INPUT FLANGE

SG IRON BS EN 1563 EN-GJS-450-10

27

OUTPUT SLEEVE

STEEL TO BS 970 GRADE 080M40(EN8) or GB699-88


GRADE 45

INDICATOR PLATE

MILD STEEL PLATE

29

WORM QUADRANT

BS1400 HTB3/BS EN 1982CC7625/ASTMB584 UNS


C86300 (MANGANESE BRONZE)

30

KEY 12X8X55

KEY STEELTO BS 4325 PART 1

31

KEY 8X7X55 SS

STAINLESS STEEL

32

LOCKNUT

STEEL BS3692 GRADE 8ZINC PLATED

33

NORDLOCK WASHER

STAINLESS STEELGRADE 316

34

NORD-LOCK WASHER

STAINLESS STEEL316

16

35

NORDLOCK WASHER

STEEL ZINC PLATED

36

NORDLOCK WASHER

STAINLESS STEEL

37

OLITE BUSH

OIL IMPREGNATED BRONZE

38*

PAINT PE3

PRIMER PAINT PE3

39

RIVET 4 X 3/16"

STAINLESS STEELGRADE A2

40

SOCKET HEAD CAP SCREW

STAINLESS STEELGRADE A4/80

41

SOCKET HEAD CAP SCREW

STAINLESS STEELGRADE A4-80

42

SOCKET HEAD CAP SCREW

STEEL GRADE 12.9ZINC PLATED

43

SOCKET HEAD CAP SCREW

STEEL GRADE 12.9ZINC PLATED

44*

SILICONE SEALANT

SILICONE

REGINA HOUSE
RING ROAD
BRAMLEY
LEEDS
WEST YORKSHIRE

1
27

ISOMETRIC
41
7
39

6.5 kg

28

ROTORK GEARS

21

16

36
25

24
4

11

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

23
34

O 140.00
5.512" PC

36
95.32

41

O 95.27
3.753"

3.751"
SPIGOT RECESS

32
43

11

30.00

14
29

O 29.95
1.181"

19
4
2

SCRAP VIEW INPUT


1:6

20

1.179"

8
26
6

30
37

33

18
22

5
40

0.40 L

13

10

34

17

15

31

0.10 L

UNLESS OTHERWISE SPECIFIED:


1. ALL DIMENSIONS IN MM

WEIGHT: 241.86 kg

DRAWN:-

J DODD 09/04/2010
C FLESHER 09/04/2010

CHECKED:-

SCALE

1 : 14 (A3)

AWWA C504-06 IW85

PROJECT:- AWWA C504-06 720:1 IW85GEARBOX.

18

HEAT
TREATMENT

PROTECTIVE
TREATMENT

SUITABLY PROTECT
FOR STORAGE

IW8A502

POWER TERMINALS
M5 x 0.8p x 6.5mm FULL THREAD
B

CONTROL TERMINALS
M4 x 0.7p x 6mm FULL THREAD

01 012204 RAR First Issue.


Issue

Date

Modification Details

Initials
Title

R.RIOCH

Rotork Controls Inc


Rochester, NY 14624

Drawn

Telephone (585) 328-1550


Fax
(585) 328-5848

Material & Spec.

http://www.rotork.com

Projection

CUSTOMER SIDE OF IQ TERMINAL BLOCK

Treatment

Checked

TLW

Date

01/22/2004
B

N/A

Scale

Do Not
1:1 Scale

PRE-PRODUCTION ISSUE
INDICATED WITH LETTER.
PRODUCTION ISSUE
INDICATED WITH NUMERAL

Part Number

Issue No Sheet No

DOC1522 01

N/A

19

of

RotorkIQMKIISize2Actuator

PublicationNumber
DOC755 2
DateofIssue12/08

2
3

39

6
37

35

8
9

33

31

38
36

29
22

34
30

21

23

65

14

15

27

20

12

13

28

32

10

11

16

17

60

64

24
25
43

26
42

19

60

18

61
66

62
67

63

68

69
70

72

48
41

47
44
45

76
77

49

49

50

52

51

71

73

78
74

81
82

53

46
54

83

55

56

PleasecontactRotorkwhenorderingparts.
Somepartsmayonlybesuppliedinmodules,
containingagroupofparts.

75

57

79
80

58

20

59
TAG: CS-BFV-9, CS-BFV-10

Sheet

1 of 2

IQMKIISize2Actuator

PublicationNumber
DOC755 2
DateofIssue12/08

ItemNumber

Description

ItemNumber

Description

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

Handwheel
Oilseal
BallBearing
ORing
HandwheelRetainer
ORing
SpringRetainingRing
ClutchSpring
CentreColumn
SlidingCoupling
DowelPin
Wormwheel
Yoke
BevelGear
BatteryPlug
ORing
BatteryRetainer/RemovalStrap
Plug
SpringHandAuto
Jack/FingerHandAuto
ORing
HandAutoLever
Screw
TransferBushSleeve
PiezoSensor
ORing
ThrustPlate
Shim
SiliconePad
BearingThrustPlate
RetainerMotorLoom
ScrewHex
BallBearing
OilSeal
LocknutFuji
Wormshaft
ShroudWormshaft
BallBearing
MotorShaft
ORing
Rotor&Stator
MotorCover
CapScrew
TerminalBung
TerminalBungRetainer
PowerScreen
ORing
TerminalCover

49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83

ORing
BallBearing
BearingRetainer
BearingRing
ThrustBase
Washer
SetScrew
DriveBush
ScrewedRing
BaseRing
CapScrew
Plug
SpringHandAuto
Jack/FingerHandAutoFinger
ORing
HandAutoLever
Screw
ShroudBevelShaft
OilSeal
ResolverShaft
PCBResolver
Washer
PanScrew
MouldedMagneticRing
BevelShaftSpring
PoziPanScrew
Transformer&PCB
Nut
Chassis
ABBContactor
CapScrew
CapScrew
RelayBoard
MainPCB&OptionBoards
ElectronicsCover

PleasecontactRotorkwhenorderingparts.
Somepartsmayonlybesuppliedinmodules,
containingagroupofparts.

21

TAG: CS-BFV-9, CS-BFV-10

Sheet

2 of 2

BritishStandardsforMaterial
CrossReferencedtoASTM

22

Capacity is .63 pints

SEE LUBRICATION SCHEDULE

TAG: CS-BFV-9, CS-BFV-10

2.C.3 - 98

23

5.00
TAG: CS-BFV-9, CS-BFV-10

2.00

7.50

47.00

41.00

32.00

22.50

28.00

START LINE FOR SERIAL


NUMBER BARCODE

55.70
20.00

43824-10

APPROVED
Service
585 247 2304

PRODUCT OF
THE USA

5.00

39.50

35.00

30.50

SPACE FOR SERIAL


NUMBER BARCODE

26.00

21.50

BRITISH PATENT No.GB 2327763


Foreign Patents pending

FM

15.00

4.50
13.50

4.50

Temp.code
Lubrication
Motor rating
min.
kW
Motor supply
Nominal motor
Amp
current
Indication Amps Vac Vdc
contacts
5 120 30
Actuator weight
kg
Year of manufacture

9.00

9.00

675 MILE CROSSING BLVD.


ROCHESTER, NY 14624, USA
Serial No.
Wiring
diagram
size
base coupling
Actuator
type
Model
IQFM
Speed
rpm
Nm
Torque max.
NEMA/Enclosure 6/WT

18.00

www.
.com
ROTORK CONTROLS INC.

10.50

13.50

Certified Product
No modifications permitted
without the approval of the
Certification Engineer

10 041110 PMJ EC3677 BARCODE SPACE ADDED.TEXT REARRANGED


9

Issue

290410 PMJ EC3539


Initials Eng.Chg No

Date

Title
Rotork Controls Limited
Bath, England BA1 3JQ.
Telephone 01225 -733200
Telefax
01225 -333467
mail @ rotork.co.uk
http://www.rotork.com

CERT STAMP ADDED


Modification Details

NAMEPLATE FM ROCHESTER (USA MANF)

Drawn

M WILLIAMS

Checked

PGC

Refer to Rotork Spec: _


Material & Spec.

Job No. _
Make from Part No: 43756

ALUMINIUM BS1470 NS4

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.

24

Scale

1:1
A3

Projection

Do Not
Scale

Ref for 1:1 Scale


10
20

Part Number

30mm
1"

Issue No Sheet No

43824 10
8

1 of 1

Di
s
s co
No witc nne
h c
n
En -fus es t
clo ib
se le
d

eOT Enclosed switches


Approximate dimensions
eOT16_ - eOT45U
eOT16_, eOT32_

(enclosure size 1)
0,18
4,5

in
mm

0,79
20
0,29
7,40

2,99
76

5,98
152

1,18
30

I ON

O OFF

5,98
152

5,51
140

0,09
R2,25

6,35
161,4
1,97
50

3,94
100

1/2 "
3/4 "
M25

4,55
115,5

EOT32U_ , EOT45U_

eOT45U_

1,36
34,5

3,19
81

Knock-outs M20

Handle OHB 2AJ

Knock-outs on top and bottom

(enclosure size 2 with selector handle)

mm
in

30.5
1.20

146
5.75

188
7.40

20
0.79
40.3
1.59

88
3.46

200
7.87
188
7.40
176
6.93

3/4 " 1 "

4.5
0.18

73
2.87

103.5
4.07
138
5.43

3/4 " 1 "

34.5
1.36

EOT32U_ , EOT45U_

eOT45U_

(enclosure size 2 with pistol grip handle)

mm
in

30.5
1.20

146
5.75

188
7.40

20
0.79
40.3
1.59

88
3.46

200
7.87
188
7.40
176
6.93

3/4 " 1 "

3/4 " 1 "

18
73
2.87

4.5
0.18

103.5
4.07
148.5
5.84

45
1.77

TAG: CS-BFV-9, CS-BFV-10

Low Voltage Products & Systems


ABB Inc. 888-385-1221 www.abb.us/lowvoltage

25

18.39
1SXU000023C0202

TAG: CS-BFV-9, CS-BFV-10

26

Document Title:

STANDARD IQ/IQT REMOTE CONTROL CIRCUITRY (24VDC)

THE INFRA RED SETTING TOOL ENABLES ALL CONFIGURABLE


ACTUATOR SETTINGS TO BE MADE.

NOTE:
ACTUATOR REMOTE CONTROL SIGNALS MAY BE INTERNALLY OR
EXTERNALLY SUPPLIED.

BEFORE PUTTING THE ACTUATOR INTO SERVICE, IT MUST BE


INSTALLED AND COMMISSIONED IN ACCORDANCE WITH
PUBLICATION E170E (IQ) or E175E (IQT) INSTALLATION AND
MAINTENANCE INSTRUCTIONS.
UNLESS SPECIFIED WITH ORDER, THE ACTUATOR IS
DESPATCHED WITH DEFAULT SETTINGS AS LISTED IN
PUBLICATION E170E (IQ) or E175E (IQT).

INTERNALLY SUPPLIED:

LINK '#' AS SHOWN AND CONNECT REMOTE CONTROL


# FIT
CONTACTS 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 IQ/IQT CONTROL AND MONITORING FACILITIES, REFER TO


PUBLICATION E120E.

FORM A

36

40

34

35

OPEN/CLOSE PUSH TO RUN CONTROL


(LOCAL CONTROL REMAINS SELF MAINTAINED)

EM
ER
GE
NC
YS
HU
TD
OW

33

INT
E
24V RNA
DC L SU
+V PPL
E
Y

OP
EN

MA
INT
AIN

CL
OS
E

INT
E
-VE RNA
L

SU
PP
LY

CUSTOMER CONNECTION FOR


REMOTE CONTROL

CO
M
CO MON
N
F
60V TRO OR R
AC LS U EM
OR P T OTE
CO
DC O
MM
CO ON
N
F
120 TRO OR R
V A LS 6 EM
C
0V
O
TO TE

FOR CONTROL FORMS D & E, LINK '#' MUST BE FITTED.


CONNECT ZERO/-VE AS INDICATED ABOVE.

25

Open

Close

To external supply or terminal 5


(see 'Note:' above)

FORM B

36

40

33

OPEN/CLOSE MAINTAINED CONTROL


WITH MID TRAVEL REVERSAL

36

40

33

Open

34

36

40

33

25

34

Stop

35

25

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

36

40

33

Open

34

35

25

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

31

32

33

EMERGENCY SHUT-DOWN CIRCUIT.


THE ESD CIRCUIT CAN BE ADDED TO ANY OF THE CONTROL
CIRCUITS SHOWN ABOVE.
AN ESD SIGNAL APPLIED TO THE ACTUATOR WILL OVERRIDE
ANY EXISTING OPEN OR CLOSE CONTROL SIGNAL.
THE DEFAULT ESD CONFIGURATION IS "STAY PUT", DERIVED
FROM A N/O CONTACT (SIGNAL APPLIED).
FOR OTHER CONFIGURABLE ESD SETTING OPTIONS, REFER TO
PUBLICATION E170E (IQ) or E175E (IQT) INSTALLATION AND
MAINTENANCE INSTRUCTIONS.
ROTORK CONTROLS LTD ROTORK CONTROLS INC
ROCHESTER
ENGLAND
NY 14624, USA

.com BATH, BA1 3JQ

Open

Close

TWO WIRE CONTROL, ENERGISE TO CLOSE


DE-ENERGIZE TO OPEN
(CONFIGURE FOR CLOSE PRIORITY)
CUSTOMER TO LINK 5 - 35
4

35

Close

TWO WIRE CONTROL, ENERGISE TO OPEN


DE-ENERGIZE TO CLOSE.
(CONFIGURE FOR OPEN PRIORITY)
CUSTOMER TO LINK 5 - 33

www.

25

To external supply or terminal 5


(see 'Note:' above)

OPEN/STOP/CLOSE MAINTAINED CONTROL

FORM F

To external supply or terminal 5


(see Note:' above)

FORM C

FORM E

35

Close

FORM D

34

34

35

25
ESD
switch
(stayput)

To external supply or terminal 5


(see 'Note:' above)

TAG: CS-BFV-9, CS-BFV-10

This is an Associative Document that needs to be read in


conjunction with the appropriate Rotork Wiring Diagram.

27

Document No

Issue No

RWS300 2

A4

IQ Electric Motor Actuator Data Sheet


Job Number

B43422

Line:

Contract Eng.:
Project:

Date:

10/04/2011

CITRUS PS SACRAMENTO, CA

Consultant:
MOV Tag No.'s:

1394663

Shop Drawing:

B4342201

CUSTOMER DATA
Name:

VALVE DATA
DEZURIK INC.

Make:

P.O. No.:

770548

Size:

P.O. Item:

1394663

Type:

Cust. Part Number:

Class:

db 3111794

ACTUATOR DATA
Model No.:
Base:
Actuator/Gear Weight:
Enclosure:
Rated Torque:
Stall Torque Range:

Handwheel Type:

IQ12FA10B4

Paint Spec.:

FA10
559 lbs

12:1 SIDE
**MI0R00208

Conduit 1 & 3:

ASA 1.0''

NEMA 4/6

Conduit 2:

ASA 1.5''

60 lbft

Conduit 4:

None

84 - 144 lbft

Wiring Diagram:

3010-000

Operating Time:

251 sec

Lubrication:
Operating Temp.:

HYDRA GB
-30C TO +70C

** Beige paint to be Federal Standard 595 Color


(January 2008) No. 26521

MOTOR DATA
Locked Rotor Amps:

5.35

Supply V/Ph/Hz:

Rated Load Amps:

1.7

Insulation Class/Duty:

480V / 3Ph / 60Hz


F / 15 min

*Nominal Load Amps:

1.2 A

Service Factor

*Nom. Motor HP:

0.34

Type:

Totally Enclosed Non-Ventilated

Rotork Gears

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

SECONDARY GEARBOX DATA


Model Number/Size:

IW8R

Make:

Ratio:

720:1'

Lubrication:

Combined Torque:

Gearbox Base:

17100 lbft

TAG: CS-BFV-9, CS-BFV-10

28

Grease
FA25

Rotork Controls, Inc.


675 Mile Crossing Blvd.
Rochester, New York
14624

Motor Data B43422

Voltage
Phases
Frequency
NominalPowerrunningtorque
NominalPowerlockedrotortorque
Currentrunningtorque
Currentlockedrotortorque
Speed

29

480
3
60
.26Kw
3.8Kw
1.16Amps
5.35Amps
43RPM

Rotork Controls, Inc.


675 Mile Crossing Blvd.
Rochester, New York
14624

Relay Data B43422

RelayOperationTime
RelayPickupVoltage
RelayDropoutVoltage
RelayCurrentofControls
AuxiliaryDeviceCoils

30

300milliseconds
24vdc
3vdc
5mA
N/A

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

Instruction DP00038
June 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. Only
persons 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 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.

WARNING Damage to protective coatings should be correctly rectified and may


invalidate warranty.
Contents
1. Introduction
2. Health and safety
3. Storage
4. Unpacking
5. Handling
6. Installation & maintenance Worm Combinations
7. Installation & maintenance- multi-turn IB & IS range combinations
8. Reference
1. Introduction
Unless otherwise specified the gearbox is supplied assembled. In the case of 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 combination
installation.

2. Health and safety


This manual is produced to enable a competent user to install, operate, adjust and inspect Rotork
gearboxes. 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 other
relevant manuals. The user and those persons working on this equipment should be familiar with
their 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 Rotork
products be required, it will be provided on request.

RG-INSTALL-003
Date 27/08/2009

Page 1

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 certification
requirements.
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: 0C to 40C (32F 104F).

4. Unpacking
Gearboxes 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. Packaging
should 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.

RG-INSTALL-003
Date 27/08/2009

Page 2

33

6. INSTALLATION OF WORM COMBINATIONS


6.1 Output sleeve removal, machining and refitting
Gearbox sizes IW12 to IW16 have an output which will be directly machined as specified with
order. 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 and
must 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 shown
on the label on the underside of the indicator or cover plate.
Retaining
Screws
Serrated
Washers
Indicator cover
O-rings
Output Sleeve

Fig.1 shows the removal of the output sleeve from the gearbox. See Fig.2 for removing the output
sleeve 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 ingress
or 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 torque
required 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.

RG-INSTALL-003
Date 27/08/2009

Page 3

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 each
screw 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 any
excess 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 screws
immediately after the sealant is applied to the indicator/cover plate and screws. Any delay
will 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 increased
weight and change of centre of gravity resulting from the addition of the gearbox
combination.
If the gearbox has been supplied with a handwheel, it is recommended that this be fitted to the
gearbox before mounting onto the valve. This will make it easier to rotate the gearing to pick up
on the valve stem, either key, flats or square.
1) Ensure gearbox output is in the same relative position as the valve shaft (open or
closed). Gearbox output position can be moved by rotating the input shaft or turning the
actuator handwheel.

RG-INSTALL-003
Date 27/08/2009

Page 4

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 the
valve opening and closing operations can be visibly checked. Once installed within the pipe the
stops 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. The
gearbox open and closed stop screws should then be set. See Fig. 4. Close the valve, using the
actuator where applicable. Use the indicator plate (2) pointer as an indication of position. Loosen
the 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 near
rated torques. It is recommended that regular maintenance occurs to verify baseplate screws (10)
are correctly torqued.

RG-INSTALL-003
Date 27/08/2009

Page 5

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
Fuchs

Name
Renolit CL-X2

Temperature Range
-60C to +120C

MOW RANGE
Manufacturer
Fuchs

Name
Renolit LST 0

Temperature Range
-20C to +120C

MTW RANGE
Manufacturer
Fuchs

Name
Renolit EPLITH 00

Temperature Range
-10C to +120C

An equivalent extreme pressure lubricant may be used.


For extreme temperature applications, please consult Rotork Gears

RG-INSTALL-003
Date 27/08/2009

Page 6

37

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:


LX-EP2 (High temp) max temp 160 C:
NO-TOX EP2 (Food) max temp 204 C:
MO2 (Graphite) max temp 120 C:
G110 (Nuclear) max temp 150 C:
G130 (Nuclear) max temp 150 C:
LST 0 (Oil for MTW,MOW) max temp 135 C:
EPLITH 00 (MTW) max temp 120 C:

Ignition temperature > 250


Ignition temperature > 250
Ignition temperature > 250
Flash point > 200 C
Flash point > 200 C
Flash point > 200 C
Ignition temperature > 250
Ignition temperature > 250

C
C
C

Nitrile (Standard) max temp 150 C:


Viton (High temp/ Nuclear) max temp 200 C:
Fluorosilicone (Low temp) max temp 225 C:
Silicone sealant max temp 200 C:

Ignition temperature > 300


Ignition temperature > 315
Ignition temperature > 300
Ignition temperature > 450

C
C
C
C

Seals

Gearbox Detail

C
C

Gearbox Specification

Gearbox design Life

IW:
MTW:
MOW:

10000 cycles at one third maximum torque


10000 output revolutions at one third maximum torque
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 ratios
greater than 720:1 to operate at this speed)

Maximum bending moment on the input flange

F10:
F14:
F16:
F25:
F30:

Maximum operating temperature

Indicated on the nameplate

Gearbox weight

Indicated on the nameplate

200Nm
340Nm
520Nm
1450Nm
1580Nm

C.F. 07.07.06 issue 3


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

38

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 customers 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.
2.
3.

The valve spindle must be greased before assembly of the gearbox to the valve.
Flanges to be sealed on assembly with silicone sealant.
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 manufacturers 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
SCREW
SIZE

M4
M5
M6
M8
M10
M12
M16
M20
M24
M30
M36

TORQUE
TIGHTNESS
(Nm)

2
5
9
21
41
71
177
346
598

TORQUE
TIGHTNESS
(lbsft)

2
4
6
15
30
53
131
255
441

HEXAGON HEAD GRADE 8.8


WITH NORDLOCK WASHER
TORQUE
TORQUE
TIGHTNESS
TIGHTNESS
(Nm)
(lbsft)

3
6
10
25
49
86
213
415
718

2
4
8
18
36
63
157
306
529

SOCKET HEAD GRADE 12.9


TORQUE
TIGHTNESS
(Nm)

4
8
14
35
69
121
299
584
1009
2006
3508

TORQUE
TIGHTNESS
(lbsft)

3
6
11
26
51
89
221
431
744
1480
2587

SOCKET HEAD GRADE 12.9


WITH NORDLOCK WASHER
TORQUE
TORQUE
TIGHTNESS
TIGHTNESS
(Nm)
(lbsft)

5
10
17
42
83
145
359
701
1211

4
7
13
31
61
107
265
517
893

DURLOK GRADE 12.9


SCREW GRADE 12 NUT
TORQUE
TORQUE
TIGHTNESS
TIGHTNESS
(Nm)
(lbsft)

11
19
45
86
152
372
717

Note: Once fully torque tightened


Durlok fasteners must not be re used on
Nuclear gearboxes

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

39

8
14
33
64
112
274
529

Copy of QC 40-2

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
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.1.7
4.1.8
4.1.9
4.1.10
4.1.11
4.1.12
4.1.13
4.1.14
4.1.15
4.1.16

If the worm gearbox is fitted with an input reducer see the dismantling instructions for the input
reducer to first remove the input reducer.
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.
Fully remove the output sleeve screws (11) from indicator plate (8).
Remove the indicator plate (8) and o rings (28).
Remove the output sleeve (5) where applicable.
Remove the key (20) from the worm shaft (4).
Remove the screwed fasteners (17), which secure the input housing (7) to the gearcase (1).
Remove the input housing from the gearcase.
The worm shaft can sometimes be removed at this stage by unscrewing the worm from the wormwheel
(3).
Remove the screwed fasteners (27) that secure the baseplate (2) to the gearcase.
Remove the baseplate from the gearcase.
Remove the wormwheel (3) from the gearcase.
Remove the screwed fasteners (18) that secure the end cap (6) to the gearcase and remove the end cap.
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.
Remove bearings from the input housing, end cap or gearcase.
Loosen the lock nuts (16) and remove the stop bolts (15) from the gearcase where applicable.

4.2 Re-assembly
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
4.2.8
4.2.9
4.2.10
4.2.11
4.2.12
4.2.13
4.2.14
4.2.15
4.2.16
4.2.17
4.2.18

Ensure all parts are free from dirt and bruising


On re assembly, all moving parts should be lightly lubricated with grease before refitting.
Ft the o ring (14) to the gearcase.
Fit the bearing(s) in the end cap or within the gearcase, making sure that the bearing is orientated
correctly and packed with grease.
Fit the o ring or apply sealant (25) to the end cap and secure to the gearcase with the screwed
fasteners.
Re-fit the worm shaft into the gearcase and locate with the bearing contained by the end cap.
Fit the bearing(s) in the input housing or within the gearcase, making sure that the bearing is orientated
correctly and packed with grease.
Fit the o ring (12) to the input housing.
Fit the o ring or apply sealant (25) to the input housing and secure to the gearcase with the screwed
fasteners.
Grease the worm shaft and gearcase before refitting the worm wheel.
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.
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.
Re-pack the gearcase with grease.
Fit the o ring or apply sealant (26) to the baseplate and re-fit the baseplate into the gearcase.
Re-secure the gearcase to the baseplate using the existing screws (27) using a diagonal tightening
movement.
Fit the o ring (13) into the baseplate.
Fit the output sleeve into the gearcase where applicable.
If o rings (28) are used with the output sleeve, position the o rings in the countersink holes of the
output sleeve.

C.F. 30.07.10 Issue 3


F:\Exeeco\GBOX\ENGINEER\ATEX\Instructions\Worm\Dismantle & Reassemble WormR3.doc

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:
Torque tightening figures.
Procedure for replacing old style output sleeves
Gearbox Installation Manual

IWSPARES.
Document No QC 40-2
IW-OS1
RG-INSTALL

C.F. 30.07.10 Issue 3


F:\Exeeco\GBOX\ENGINEER\ATEX\Instructions\Worm\Dismantle & Reassemble WormR3.doc

41

SPARE PARTS LIST FOR IW RANGE OF WORM GEAR ACTUATORS


21

18

25

10

17

22

12
6

20

11
23

13

FITTED TO
UNDERSIDE OF
INDICATOR PLATE

27

14
26

16

19

28

SECTION

ITEM

15

PART SECTION

DESCRIPTION

11
QTY

19

SPARES

1
2
3
4
5

GEARCASE
BASEPLATE
WORM QUADRANT
WORMSHAFT
OUTPUT SLEEVE

1
1
1
1 (IW3 -11 ONLY)

ENDCAP

7
8

INPUT FLANGE
INDICATOR PLATE

1
1

9
10

ANGULAR CONTACT BALL BEARING


SHIM

2 (IW3-8), 6 (IW9 -11), 4 (IW12-13)


1 (WHERE APPLICABLE)

11

SOCKET HEAD CAP SCREW/ DURLOCK

4 (IW3, IW12-13), 8 (IW4 -11)

12
13
14
15

O-RING
O-RING
O-RING
STOP BOLT

1
1
1
2 (IW & MOW ONLY)

16

HEX NUT

2 (IW & MOW ONLY)

17
18
19
20

SCREWED FASTENER *
SCREWED FASTENER *
NORDLOCK WASHER
KEY

4 (IW3 - 8), 8 (IW9 - IW13)


4 (IW3 -8), 8 (IW9 - IW13)
4(IW3), 8( IW4 TO 11)
1 (IW3 - IW11), 2 (IW12-13)

21

NAMEPLATE

22
23

RIVET 4 X 3/16"
LABEL - SHCS/NORDLOCK WASHER

2 FOR METAL NAMEPLATE ONLY


1

24*
25

GREASE
O-RING OR SEALANT

TO FILL GEARBOX
2

26
27

O-RING OR SEALANT
SCREWED FASTENER *

1
4 (IW3), 8 (IW4-10), 16 (IW11-13)

YES

28

O RING

4 (IW3), 8 (IW4 - IW11)

YES

28
18

8
23

22

14

21

YES
YES
YES
YES
YES

25
16

1
10

15

13

YES

26

* : 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 HAVE
THE SAME GEARBOX RATING

Rotork Gears
Regina House
Ring Road
Bramley
Leeds
England
LS13 4ET

17

20

27

TYPICAL WORM EXPLODED VIEW

C.F. 27.07.10 ISSUE 3


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

42

25
7

12

DeZURIK VENDOR
INSTRUCTIONS
ROTORK IQ RANGE ACTUATORS

Instruction DP00091
June 2011

43

This page intentionally blank.

44

IQ Range
Installation and
Maintenance Instructions

This manual contains important safety


information. Please ensure it is thoroughly
read and understood before installing,
operating or maintaining the equipment.

Publication number E170-3E


Date of issue 04/09

Including Addendeum 03-10

Addendum to:
E170-3E IQ Range Installation and Maintenance Instructions
Date 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

page 14

page 80

12
6.3 Cable Entry
The cable entries on the actuator
terminal housing are tapped either
1 NPT or 1 NPT

IQ Approvals

Refer to actuator nameplate for unit specific approval details


European Hazardous area

Conditions of Safe Use

ATEX (94/9/EC) II 2 GD c
Ex d IIB T4 Gb, Ex tb IIIC T120C Db IP68
Temperature -20 to +70C (-4 to +158F)
*Option -30 to +70C (-22 to +158F)
*Option -40 to +70C (-40 to +158F)
*Option -50 to +40C (-58 to +104F)

t 5IFGPMMPXJOHBSFUIFNBYJNVNDPOTUSVDUJPOBMGMBNFQBUIHBQT
 GPS"5&9BOE*&$&Y"QQSPWFEBDUVBUPST

Ex d IIC T4 Gb, Ex tb IIIC T120C Db IP68


Temperature -20 to +70C (-4 to +158F)
*Option -30 to +70C (-22 to +158F)
*Option -40 to +70C (-40 to +158F)
*Option -50 to +40C (-58 to +104F)

Ex de IIB T4 Gb, Ex tb IIIC T120C Db IP68


Temperature -20 to +70C (-4 to +158F)
*Option -30 to +70C (-22 to +158F)
*Option -40 to +70C (-40 to +158F)
*Option -50 to +40C (-58 to +104F)

Ex de IIC T4 Gb, Ex tb IIIC T120C Db IP68


Temperature -20 to +70C (-4 to +158F)
*Option -30 to +70C (-22 to +158F)
*Option -40 to +70C (-40 to +158F)
*Option -50 to +40C (-58 to +104F)

4
IQ MAXIMUM FLAMEPATH GAPS
Flamepath






















.PUPS$PWFS(FBSDBTF




8PSNTIBGU4ISPVE(FBSDBTF


8PSNTIBGU4ISPVE(FBSDBTF


8PSNTIBGU8PSNTIBGU4ISPVE


8PSNTIBGU8PSNTIBGU4ISPVE
5FSNJOBM#VOH(FBSDBTF **#

5FSNJOBM#VOH(FBSDBTF **$

5FSNJOBM$PWFS(FBSDBTF
&MFDUSJDBM$PWFS(FBSDBTF
3FTPMWFS4IBGU3FTPMWFS4IBGU#VTI
3FTPMWFS4IBGU#VTI(FBSDBTF

.PUPS-PPN#VTI(FBSDBTF





4UBUPSMPDLJOH1JO.PUPS$PWFS



%$.PUPS"EBQUPS(FBSDBTF
%$.PUPS$07&3%$.PUPS$PWFS"EBQUPS

Max. Gap (mm)
































Min Length (mm)
































/PUF/FHBUJWF4JHOEFOPUFTBOJOUFSGFSFODFGJU
t
5IFBDUVBUPSNVTUPOMZCFMPDBUFEXIFSFUIFSJTLPGJNQBDUVQPOUIFXJOEPXJTMPX

46

Actuator Type and Size


*2 *2 *2 *2 *2 *2
*2. *2. *2. *2.
*24 *24 *24
*2 *2 *2 *2 *2
*2 *2 *2 *2. *2. *24
*2% *2% *2%
*2 *2 *2. *2. *24
*2% *2% *2) *2)
*2 *24 *2)
*2 *2 *2 *2 *2 *2)
*2 *2 *2 *2. *2. *24
*2% *2% *2%
*2 *2 *2. *2. *24
*2% *2% *2) *2)
*2 *24 *2)
*2 *2 *2 *2 *2 *2)
"MM5ZQFTBOE4J[FT
"MM5ZQFTBOE4J[FT
"MM5ZQFTBOE4J[FT
"MM5ZQFTBOE4J[FT
"MM5ZQFTBOE4J[FT
"MM5ZQFTBOE4J[FT
"MM5ZQFTBOE4J[FT
*2 *2 *2 *2. *2. *24
*2 *2 *2. *2. *24
*2 *24 *2)
*2% *2% *2% *2% *2%
*2% *2% *2% *2% *2%

4IPVMEZPVSFRVJSFUFDIOJDBMBTTJTUBODFPSTQBSFT 3PUPSLHVBSBOUFFTUIFCFTUTFSWJDFJOUIFXPSME$POUBDUZPVSMPDBM
3PUPSLSFQSFTFOUBUJWFPSUIFGBDUPSZEJSFDUBUUIFBEESFTTPOUIFOBNFQMBUF RVPUJOHUIFBDUVBUPSUZQFBOETFSJBMOVNCFS

UK
Rotork plc
tel
+44 (0)1225 733200
fax
+44 (0)1225 333467
email
mail@rotork.com

"GVMMMJTUJOHPGPVSXPSMEXJEFTBMFT
BOETFSWJDFOFUXPSLJTBWBJMBCMFPO
PVSXFCTJUFBU
www.rotork.com

USA
Rotork Controls Inc.
tel
+1 (585) 247 2304
fax
+1 (585) 247 2308
email
info@rotork.com

As part of a process of on-going product


EFWFMPQNFOU 3PUPSLSFTFSWFTUIFSJHIU
to amend and change specifications
XJUIPVUQSJPSOPUJDF

5IFOBNF3PUPSLJTBSFHJTUFSFEUSBEFNBSL
3PUPSLSFDPHOJ[FTBMMSFHJTUFSFEUSBEFNBSLT
1VCMJTIFEBOEQSPEVDFEJOUIF6,CZ
3PUPSL$POUSPMT-JNJUFE

1VCMJTIFEEBUBNBZCFTVCKFDUUPDIBOHF

1084)

'PSUIFWFSZMBUFTUWFSTJPOSFMFBTF WJTJU
PVSXFCTJUFBUXXXSPUPSLDPN

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

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.
Rotork Setting Tool Pro

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

47

II

This manual provides instruction on:


* Manual and electrical (local and remote) operation.

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 up
procedures, non-intrusive setting of torque levels, position limits and all
other control and indication functions can be made safely, quickly and
conveniently, even in hazardous locations. The IQ allows commissioning
and adjustment to be carried out with the main power supply to the
actuator switched on or off.

* 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.

Standard diagnostics access information about the control system, valve


and 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 actuator
with a single key press of the Setting Tool.

* Sales and Service.

Refer to Publication E180E2 for repair, overhaul and


spare part instructions.

The on board Datalogger captures operational and valve torque data


enabling informed maintenance choices to be made. IQ Insight software
for 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 yellow
label 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.

III

Identifying Actuator Parts

Battery sealing plug


Metal (8mm Allen key required)
Plastic (10mm Allen key required)
as appropriate.

Name plate

Display window

Side hand wheel


Grease nipple (if fitted)

Hand wheel
Oil plug
Hand / Auto
lever

Control Cover

Oil plug

Motor

Base

Terminal Cover

Local / Remote / Stop


selector

Conduit entries

Open / Close selector

48

Oil plug

CONTENTS

1
Page

1 Health and Safety

2 Storage

3 Operating your IQ Actuator

3.1
3.2
3.3
3.4
3.5
3.6

Operating by Hand
Operating Electrically
Display Local Indication
Display Status Indication Travel
Display Status Indication Control
Display Alarm Indication

4 Preparing Drive Bush


4.1
4.2
4.3
4.4

IQ10 to IQ35
Thrust Base Types A and Z
IQ10 to IQ35
Non-Thrust Base Type B
IQ40 to IQ95
Thrust Base Types A and Z
IQ40 to IQ95
Non-Thrust Base Type B

7
8
8
9

5 Mounting the Actuator


5.1
5.2
5.3
5.4

3
3
4
5
5
5

10

Rising Stem Valves Top Mounting


Valve with Gearbox Side Mounting
Non-Rising Stem Valves Top Mounting
Handwheel Sealing

11
12
12
12

Page
5.5
5.6
5.7

IQM Modulating Actuators


IQML Linear Drive Unit
IQML Adjusting Linear Stroke

6 Cable Connections
6.1
6.2
6.3
6.4
6.5

14

Earth/Ground Connections
Removing Terminal Cover
Cable Entry
Connecting to Terminals
Replacing Terminal Cover

7 Commissioning
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9

12
12
13

14
14
14
15
15

16

The Setting Procedure


The Rotork Setting Tools
Entering the Actuator
Setting Procedure
Setting Mode Password
New Password
Checking Mode
Crossroad
The Actuator Display
Setting/Checking Mode
Returning to Valve Position Display

8 Commissioning
Basic Settings

16
17
20
20
20
20
21
21

Page

9 Commissioning
Configuration Settings
Configuration Settings Contents
Default Options

10 Maintenance, Monitoring
and Troubleshooting
10.1
10.2
10.3
10.4

Setting Tool Pro Download & Upload


Help Screens
IQ Infrared Diagnostic & Configuration
Environmental

11 Weights and Measures


Binary, Hexadecimal and Decimal
Conversion Table

31
33
63

65
68
71
76
77

78
79

12 IQ Approvals

80

Approved Fuses

81

Appendix A

82

21

22

Basic Settings Contents

23

Health and Safety

This manual is produced to enable a


DPNQFUFOUVTFSUPJOTUBMM PQFSBUF 
BEKVTUBOEJOTQFDU3PUPSL*2SBOHFWBMWF
BDUVBUPST0OMZQFSTPOTDPNQFUFOUCZWJSUVF
PGUIFJSUSBJOJOHPSFYQFSJFODFTIPVMEJOTUBMM 
NBJOUBJOBOESFQBJS3PUPSLBDUVBUPST
Work undertaken must be carried out in
BDDPSEBODFXJUIUIFJOTUSVDUJPOTJOUIJTBOE
BOZPUIFSSFMFWBOUNBOVBMT5IFVTFSBOE
UIPTFQFSTPOTXPSLJOHPOUIJTFRVJQNFOU
TIPVMECFGBNJMJBSXJUIUIFJSSFTQPOTJCJMJUJFT
VOEFSBOZTUBUVUPSZQSPWJTJPOTSFMBUJOHUP
UIF)FBMUIBOE4BGFUZPGUIFJSXPSLQMBDF
%VFDPOTJEFSBUJPOPGBEEJUJPOBMIB[BSET
TIPVMECFUBLFOXIFOVTJOHUIF*2SBOHF
PGBDUVBUPSTXJUIPUIFSFRVJQNFOU4IPVME
further information and guidance relating
UPUIFTBGFVTFPGUIF3PUPSL*2SBOHFPG
BDUVBUPSTCFSFRVJSFE JUXJMMCFQSPWJEFE
POSFRVFTU
5IFFMFDUSJDBMJOTUBMMBUJPO NBJOUFOBODF
and use of these actuators should be
DBSSJFEPVUJOBDDPSEBODFXJUIUIF
/BUJPOBM-FHJTMBUJPOBOE4UBUVUPSZ
1SPWJTJPOTSFMBUJOHUPUIFTBGFVTFPG
UIJTFRVJQNFOU BQQMJDBCMFUPUIFTJUF
PGJOTUBMMBUJPO
'PSUIF6,&MFDUSJDJUZBU8PSL|3FHVMBUJPOT
BOEUIFHVJEBODFHJWFOJOUIF
applicable edition of the IEE Wiring
3FHVMBUJPOTTIPVMECFBQQMJFE"MTPUIF
VTFSTIPVMECFGVMMZBXBSFPGIJTEVUJFT

VOEFSUIF)FBMUIBOE4BGFUZ"DU
'PSUIF64"/'1" /BUJPOBM&MFDUSJDBM
$PEFJTBQQMJDBCMF
The mechanical installation should be
carried out as outlined in this manual
BOEBMTPJOBDDPSEBODFXJUISFMFWBOU
standards such as British Standard Codes
PG1SBDUJDF*GUIFBDUVBUPSIBTOBNFQMBUFT
indicating that it is suitable for installation
JOIB[BSEPVTBSFBTUIFOUIFBDUVBUPSNBZ
CFJOTUBMMFEJO;POF ;POF ;POF
BOE;POF PS%JWPS%JW DMBTT*
PS$MBTT**
DMBTTJGJFEIB[BSEPVTBSFB
MPDBUJPOTPOMZ*UTIPVMEOPUCFJOTUBMMFE
JOIB[BSEPVTBSFBMPDBUJPOTXJUIBO
JHOJUJPOUFNQFSBUVSFMFTTUIBO$ 
VOMFTTTVJUBCJMJUZGPSMPXFSJHOJUJPO
temperatures has been indicated on the
BDUVBUPSOBNFQMBUF
*UTIPVMEPOMZCFJOTUBMMFEJOIB[BSEPVT
BSFBMPDBUJPOTDPNQBUJCMFXJUIUIFHBT
HSPVQTTUBUFEPOUIFOBNFQMBUF
5IFFMFDUSJDBMJOTUBMMBUJPO NBJOUFOBODF
and the use of the actuator should be
DBSSJFEPVUJOBDDPSEBODFXJUIUIFDPEF
PGQSBDUJDFSFMFWBOUGPSUIBUQBSUJDVMBS
)B[BSEPVT"SFBDFSUJGJDBUJPO
No inspection or repair should be
undertaken unless it conforms to the
TQFDJGJDIB[BSEPVTBSFBDFSUJGJDBUJPO
SFRVJSFNFOUT6OEFSOPDJSDVNTUBODFT
TIPVMEBOZNPEJGJDBUJPOPSBMUFSBUJPO

be carried out on the actuator as this


DPVMEJOWBMJEBUFUIFBDUVBUPSTIB[BSEPVT
BSFBBQQSPWBMDFSUJGJDBUJPO"DDFTTUP
MJWFFMFDUSJDBMDPOEVDUPSTJTGPSCJEEFOJO
UIFIB[BSEPVTBSFBVOMFTTUIJTJTEPOF
VOEFSBTQFDJBMQFSNJUUPXPSL PUIFSXJTF
BMMQPXFSTIPVMECFJTPMBUFEBOEUIF
BDUVBUPSNPWFEUPBOPOIB[BSEPVTBSFB
GPSSFQBJSPSBUUFOUJPO

WARNING: Motor Temperature


Under normal operation the temperature
PGBDUVBUPSTNPUPSDPWFSTVSGBDFTDBO
FYDFFE$BCPWFBNCJFOU
WARNING: Thermostat Bypass
*GUIFBDUVBUPSJTDPOGJHVSFEUPCZQBTT
UIFNPUPSUIFSNPTUBUUIFOUIFIB[BSEPVT
BSFBDFSUJGJDBUJPOXJMMCFJOWBMJEBUFE
"EEJUJPOBMFMFDUSJDBMIB[BSETNBZPDDVS
XIFOVTJOHUIJTDPOGJHVSBUJPO5IF
VTFSTIPVMEFOTVSFUIBUBOZOFDFTTBSZ
BEEJUJPOBMTBGFUZNFBTVSFTBSFDPOTJEFSFE
WARNING: Control and Indication
8IFSFUIFBDUVBUPSCVJMEBMMPXTSFNPUF
control and indication supplies higher
UIBO7"$CVUCFMPX7"$ SFGFS
UPBDUVBUPSXJSJOHEJBHSBN
UIFBDUVBUPS
installation altitude must be restricted
UPMFTTUIBONBTEFGJOFECZ#4&/
PS*&$ 4BGFUZ3FRVJSFNFOUT
'PS&MFDUSJDBM&RVJQNFOUGPSNFBTVSFNFOU 

49

DPOUSPMBOEMBCPSBUPSZVTF


WARNING: Enclosure Materials


*2UP*2BSFNBOVGBDUVSFEGSPN
BMVNJOJVNBMMPZXJUITUBJOMFTTTUFFM
fasteners and the thrust bases are
NBOVGBDUVSFEJODBTUJSPO
*2UP*2FODMPTVSFTBSFNBOVGBDUVSFE
JOBMVNJOJVNBMMPZBOEDBTUJSPOXJUI
stainless steel fasteners and the thrust
CBTFTBSFNBOVGBDUVSFEJODBTUJSPO
The user must ensure that the operating
FOWJSPONFOUBOEBOZNBUFSJBMT
surrounding the actuator cannot lead
UPBSFEVDUJPOJOUIFTBGFVTFPG PSUIF
QSPUFDUJPOBGGPSEFECZ UIFBDUVBUPS
Where appropriate the user must ensure
UIFBDUVBUPSJTTVJUBCMZQSPUFDUFEBHBJOTU
JUTPQFSBUJOHFOWJSPONFOU

WARNING: Operating by Hand


8JUISFTQFDUUPIBOEXIFFMPQFSBUJPOPG
3PUPSLFMFDUSJDBDUVBUPST TFFXBSOJOHPOQ
This actuator must only be
located in areas where the risk of
impact to the viewing window is low.
WARNING: "DUVBUPSNBZTUBSUBOE
PQFSBUFXIFOSFNPUFJTTFMFDUFE5IJTXJMM
be dependent on remote control signal
TUBUVTBOEBDUVBUPSDPOGJHVSBUJPO

Storage

Operating your
IQ Actuator

*GZPVSBDUVBUPSDBOOPUCFJOTUBMMFE
JNNFEJBUFMZTUPSFJUJOBESZQMBDFVOUJM
ZPVBSFSFBEZUPDPOOFDUJODPNJOH
DBCMFT

3.1 Operating by Hand

If the actuator has to be installed but


cannot be cabled it is recommended
UIBUUIFQMBTUJDUSBOTJUDBCMFFOUSZQMVHT
BSFSFQMBDFEXJUINFUBMQMVHTXIJDIBSF
TFBMFEXJUI15'&UBQF

With 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.

The Rotork double-sealed construction


XJMMQSFTFSWFJOUFSOBMFMFDUSJDBM
DPNQPOFOUTQFSGFDUMZJGMFGU
VOEJTUVSCFE
*UJTOPUOFDFTTBSZUPSFNPWFBOZ
FMFDUSJDBMDPNQBSUNFOUDPWFSTJOPSEFS
UPDPNNJTTJPOUIF*2BDUVBUPS
3PUPSLDBOOPUBDDFQUSFTQPOTJCJMJUZGPS
deterioration caused on-site once the
DPWFSTBSFSFNPWFE
&WFSZ3PUPSLBDUVBUPSIBTCFFOGVMMZ
UFTUFECFGPSFMFBWJOHUIFGBDUPSZUP
HJWFZFBSTPGUSPVCMFGSFFPQFSBUJPO 
QSPWJEJOHJUJTDPSSFDUMZDPNNJTTJPOFE 
JOTUBMMFEBOETFBMFE

WARNING

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.

5PFOHBHFIBOEXIFFMESJWFEFQSFTTUIF
)BOE"VUPMFWFSJOUPi)BOEwQPTJUJPO
BOEUVSOUIFIBOEXIFFMUPFOHBHFUIF
DMVUDI5IFMFWFSDBOOPXCFSFMFBTFE
XIFSFJUXJMMSFUVSOUPJUTPSJHJOBM
QPTJUJPO5IFIBOEXIFFMXJMMSFNBJO
engaged until the actuator is operated
FMFDUSJDBMMZXIFOJUXJMMBVUPNBUJDBMMZ
EJTFOHBHFBOESFUVSOUPNPUPSESJWF
*GSFRVJSFEUIF)BOE"VUPMFWFSDBO
be locked in either position using a
QBEMPDLXJUIBNNIBTQ

When the selector is locked in the Local


PS3FNPUFQPTJUJPOTUIF4UPQGBDJMJUZJTTUJMM
BWBJMBCMF5IFTFMFDUPSDBOBMTPCFMPDLFE
JOUIF4UPQQPTJUJPOUPQSFWFOUFMFDUSJDBM
PQFSBUJPOCZ-PDBMPS3FNPUFDPOUSPM

3.2 Operating Electrically


$IFDLUIBUQPXFSTVQQMZWPMUBHFBHSFFT
XJUIUIBUPOUIFBDUVBUPSOBNFQMBUF
4XJUDIPOQPXFSTVQQMZ*UJTOPU
OFDFTTBSZUPDIFDLQIBTFSPUBUJPO

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
Operation
The red selector enables either Local or
3FNPUFDPOUSPM MPDLBCMFJOFBDIQPTJUJPO
VTJOHBQBEMPDLXJUIBNNIBTQ

Fig. 3.1

Local Control
With the red selector positioned at Local
BOUJDMPDLXJTF
UIFBEKBDFOUCMBDLLOPC
DBOCFUVSOFEUPTFMFDU0QFOPS$MPTF
'PS4UPQ UVSOSFELOPCDMPDLXJTF

Remote Control
Rotate the red selector to the Remote
QPTJUJPO DMPDLXJTF
UIJTBMMPXTSFNPUF
DPOUSPMTJHOBMTUPPQFSBUFUIFBDUVBUPS
-PDBM4UPQDBOTUJMMCFVTFECZUVSOJOH
UIFSFELOPCBOUJDMPDLXJTF

3.3 DisplayLocal Indication

"MBSNJOEJDBUJPOJTTVQQPSUFECZGBVMU
EFTDSJQUJPOUFYUJOUIFMPXFSEJTQMBZ
6.#BUUFSZ"MBSN*DPO5IJTJDPOXJMMCF
EJTQMBZFEXIFOBCBUUFSZJTEFUFDUFEBT
MPXPSGMBU#BUUFSZMPXPSGMBUXJMM
BMTPCFEJTQMBZFEJOUIFMPXFSEJTQMBZ

Open

Closed

5IFUXPUSJDPMPVS-&%hTXJMMCF3FE 
UIFPQFOTZNCPMBOE0QFO-JNJUXJMM
CFEJTQMBZFE

5IFUXPUSJDPMPVS-&%hTXJMMCF(SFFO 
DMPTFETZNCPMBOE$MPTFE-JNJUXJMM
CFEJTQMBZFE

Open Limit

Closed Limit

7. IR Icon - This icon flashes during infra


SFEDPNNVOJDBUJPOBDUJWJUZ
8.1FSDFOUBHF0QFO*DPO5IJTJDPOXJMM
CFEJTQMBZFEXIFOBQFSDFOUBHF0QFO
WBMVFJTJOUIFVQQFSEJTQMBZ

Fig. 3.2 The Actuator Display


5IFEJTQMBZDPOTJTUTPG
1.1PTJUJPO%JTQMBZ5IJTJTUIFNBJO
TFHNFOUQPTJUJPOEJTQMBZXJUIJDPOT
2.5FYU%JTQMBZ5IJTJTBMJOF 
DIBSBDUFSTEPUNBUSJYEJTQMBZXIJDI
BMMPXTUFYUUPCFVTFEUPDPNQMJNFOU
UIFQPTJUJPOEJTQMBZBOEJDPOT
3.*OGSB3FE-&%hT
4.Y5SJDPMPVS-&%hTGPSQPTJUJPO
JOEJDBUJPO
5."MBSN*DPO5IJTXJMMCFEJTQMBZFE
GPS7BMWF $POUSPM BOE"DUVBUPSBMBSNT

5IFMJRVJEDSZTUBMEJTQMBZTDSFFOIBT
modes of position indication:
7BMWFQPTJUJPOoQPXFSPO
7BMWFQPTJUJPOoQPXFSPGG
0OQPXFSVQUIFBDUVBUPSTMJRVJE
DSZTUBMEJTQMBZTDSFFOJTCBDLMJUXJUIBO
amber light and one of the indicator
MBNQTXJMMCFPO EFQFOEFOUPO
QPTJUJPO5IFEJTQMBZTDSFFOXJMMTIPX
QFSDFOUBHFPQFOPSBOFOEPGUSBWFM
TZNCPM(See Figs 3.3, 3.4 and 3.5)
"TTUBOEBSE SFEMBNQTJHOJGJFTWBMWF
PQFO BNCFSJOUFSNFEJBUF BOEHSFFO
MBNQTJHOJGJFTWBMWFDMPTFE0QFOBOE
DMPTFEDPMPVSGVODUJPOTDBOCFSFWFSTFE
POSFRVFTU

Fig. 3.3

Fig. 3.5

Mid Travel

8JUIUIFNBJOQPXFSTVQQMZTXJUDIFE
PGG UIFEJTQMBZTDSFFOJTQPXFSFECZ
BCBUUFSZBOEDPOUJOVFTUPEJTQMBZ
BDUVBUPSQPTJUJPO)PXFWFS UIFCBUUFSZ
EPFTOPUTVQQPSUTDSFFOCBDLMJHIUJOH 
QPTJUJPOJOEJDBUPSMBNQTPSEPUNBUSJY
EJTQMBZ

5IFUXPUSJDPMPVS-&%hTXJMMCF"NCFS 
QFSDFOUBHFPQFOWBMVFXJMMCFTIPXO
BOE4UPQQFEXJMMCFEJTQMBZFEXIFO
UIFSFJTOPBDUVBUPSNPWFNFOU

LED Indicators

Stopped

Fig. 3.4

50

WARNING: Mid Travel LED


colour may be affected by viewing
angle and lighting level.
5IF$MPTF-&%DPMPVSDBOCFDIBOHFE
UPSFEJGSFRVJSFE5IF.JE5SBWFMBNCFS
-&%DBOCFTXJUDIFEPGGJGSFRVJSFE
3FGFSUP4FDUJPO QBHF

3.4 Display Status Indication


Travel
5IF*2EJTQMBZQSPWJEFTSFBMUJNFTUBUVT
JOEJDBUJPO5IFUPQMJOFPGUIFUFYU
EJTQMBZJTSFTFSWFEGPSUSBWFMTUBUVT
JOEJDBUJPO'JHTIPXTUIFUSBWFM
TUBUVTFYBNQMFClosed Limit 

Closed Limit

t Timer Active Interrupter Timer option


 FOBCMFEPOMZ*OUFSSVQUFS5JNFSIBT
 TUPQQFEUIFBDUVBUPSNJEUSBWFMGPSB
 QFSJPEFRVBMUPUIFTFU5JNFS0GG
 UJNFRefer to 9.13 page 59.

t Remote Control Remote control


 TFMFDUFEoSFETFMFDUPS

3.5 Display Status Indication


Control

t Remote Close Remote close IBSEXJSFE


 PSBOBMPHVF
TJHOBMBQQMJFE

General Alarm:

t Remote Open Remote open IBSEXJSFE


 PSBOBMPHVF
TJHOBMBQQMJFE

Battery Alarm:

5IFCPUUPNMJOFPGUIFUFYUEJTQMBZJT
SFTFSWFEGPSDPOUSPMTUBUVTJOEJDBUJPO
BOEJTEJTQMBZFEGPSBQQSPYJNBUFMZ
seconds after the control mode or
TJHOBMJTBQQMJFE'JHTIPXTUIF
DPOUSPMTUBUVTFYBNQMFRemote Control 

t Local Close Local close signal applied


 oCMBDLTFMFDUPS
t Local Open Local open signal applied
 oCMBDLTFMFDUPS

Fig. 3.6
"WBJMBCMFUSBWFMTUBUVTDPOEJUJPOTEJTQMBZFE

t Remote Bus Close Remote Bus* close


 TJHOBMBQQMJFE
t Remote Bus ESD Remote Bus*
 FNFSHFODZTIVUEPXOTJHOBMBQQMJFE

Closed Limit
Remote Control

t Open Limit Actuator has reached the


 TFUPQFOMJNJUQPTJUJPO
t Moving Open "DUVBUPSJTUSBWFMJOHJO
 UIFPQFOEJSFDUJPO

Fig. 3.7

t Moving Closed "DUVBUPSJTUSBWFMJOHJO


 UIFDMPTFEEJSFDUJPO

t Local Control Local control selected  SFETFMFDUPS

t Stopped Actuator has stopped in a


 NJEUSBWFMQPTJUJPO JOEJDBUFEJOUIF
 UPQEJTQMBZ PQFO


t Local Stop -PDBMTUPQTFMFDUFEoSFE


 TFMFDUPS

5IF*2EJTQMBZQSPWJEFTBMBSNJOEJDBUJPO
JOUIFGPSNPGUFYUBOEBMBSNJDPOT
There are 2 alarm icons:

t Remote ESD 3FNPUFIBSEXJSFE


 FNFSHFODZTIVUEPXOTJHOBMBQQMJFE
t Remote Bus Open Remote Bus * open
 TJHOBMBQQMJFE

t Closed Limit Actuator has reached the


 TFUDMPTFEMJNJUQPTJUJPO

3.6 Display Alarm Indication

"WBJMBCMFDPOUSPMTUBUVTDPOEJUJPOTEJTQMBZFE

* Bus Control option fitted may be


Pakscan, Profibus, Modbus,
DeviceNet or Foundation Fieldbus.
Refer to actuator wiring diagram.

General Alarm
5IFHFOFSBMBMBSNJDPOXJMMCF
TVQQPSUFEXJUIUFYUJOUIFCPUUPNMJOF
JOEJDBUJOHUIFQBSUJDVMBSBMBSN PSJG
NPSFUIBOPOFJTQSFTFOU FBDIBMBSN
XJMMCFEJTQMBZFEJOTFRVFODF
'JHTIPXTUIFTUBUVTFYBNQMF

TORQUE TRIP CL 

Stopped
TORQUE TRIP CL
Fig. 3.8

"WBJMBCMFBMBSNDPOEJUJPOTEJTQMBZFE

Actuator Alarms

Valve Alarms

t THERMOSTAT TRIP Motor thermostat


has tripped due to the motor
 PWFSIFBUJOH0QFSBUJPOJTJOIJCJUFE
until the thermostat resets
 BVUPNBUJDBMMZXIFOUIFNPUPSDPPMT
 $IFDLBDUVBUPSEVUZDZDMFBHBJOTU
 QSPDFTTSFRVJSFNFOUT SVOOJOHUJNF 
 UPSRVF BNCJFOUUFNQFSBUVSF


t TORQUE TRIP CL USJQQFEPGGPOUPSRVF


 XIJMFNPWJOHJOUIFDMPTFEJSFDUJPO
t TORQUE TRIP OP USJQQFEPGGPOUPSRVF
 XIJMFNPWJOHJOUIFPQFOEJSFDUJPO
t MOTOR STALLED OPNPWFNFOU
 EFUFDUFEBGUFSBTJHOBMUPNPWF
Control Alarms
t






ESD ACTIVE &4%TJHOBMBQQMJFE8IFO


QSFTFOUUIF&4%TJHOBMPWFSSJEFTBMM
MPDBMBOESFNPUFDPOUSPMTJHOBMT
0ODFUIF&4%BDUJPOJTDBSSJFEPVU
PQFSBUJPOJTJOIJCJUFEXIJMFUIF&4%
TJHOBMJTNBJOUBJOFERefer to 9.3
ESD Action page 36

t INTERLOCK ACTIVE 0QFOBOEPSDMPTF


interlocks are configured on and are
 BDUJWFRefer to 9.3 Interlockpage 38
Operation in the direction of an
 BDUJWFJOUFSMPDL T
JTJOIJCJUFE
 /PUFUIBUXIFODPOEJUJPOBMDPOUSPMJT
 DPOGJHVSFE BOBDUJWFJOUFSMPDLXJMM
 OPUJOIJCJUMPDBMDPOUSPMPQFSBUJPO

t




PHASE LOST  QIBTFNPEFMTPOMZ




t




24V LOST 5IFWPMUDVTUPNFS

t TORQ SENSOR FAIL %FUFDUFEGBJMVSF


 JOUIFUPSRVFTFOTJOHTZTUFN
 oDPOUBDU3PUPSL
t EEPROM MISSING Contact Rotork

Battery Alarm

5IFQIBTFTVQQMZUIFBDUVBUPS
DPOOFDUFEUPUFSNJOBMJTMPTU
0QFSBUJPOJTJOIJCJUFE
TVQQMZ UFSNJOBMT
IBTUSJQQFE
$IFDLSFNPUFDPOUSPMXJSJOH4VQQMZ
JTQSPUFDUFEXJUIBSFTFUUBCMFGVTF

t LOCAL CONTROL FAIL Check operation


 PGDPOUSPMTFMFDUPST CMBDLBOESFE

t CONFIG ERROR 5IFSFNBZCFBOFSSPS
in the configuration (set up) of the
 BDUVBUPS$IFDLBOESFTFUCBTJD
setting and check configuration
 TFUUJOHT
t POS SENSOR FAIL %FUFDUFEGBJMVSFJO
 UIFQPTJUJPOTFOTJOHTZTUFNoDPOUBDU
 3PUPSL

Open Limit
BATTERY LOW
Fig. 3.7
5IFBDUVBUPSDIFDLTUIFCBUUFSZMFWFM
BUBQQSPYJNBUFMZIPVSJOUFSWBMT5IF
CBUUFSZBMBSNJDPOJTEJTQMBZFEXIFO
UIFBDUVBUPSEFUFDUTJUTCBUUFSZBTCFJOH
MPXBOEUIFEJTQMBZXJMMJOEJDBUFBATTERY
LOW 
*GUIFCBUUFSZJTGMBUPSNJTTJOHUIF
EJTQMBZXJMMJOEJDBUFBATTERY FLAT 

51

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


*G POQPXFSVQ UIFBDUVBUPSEFUFDUTB
EJTDIBSHFECBUUFSZBOEBDUVBUPSQPXFS
loss inhibit feature [OS] is enabled
(refer to page 61
CPUICBUUFSZBOE
HFOFSBMBMBSNJDPOTXJMMCFEJTQMBZFE
BOEUIFCPUUPNMJOFXJMMJOEJDBUF
BMUFSOBUFMZPWR LOSS INHIBIT and BATTERY
FLAT &MFDUSJDBMPQFSBUJPOXJMMCF
JOIJCJUFE5IFCBUUFSZNVTUCFSFQMBDFE
BOEUIFMJNJUTNVTUCFSFTFU3FGFSUP
4FDUJPO QBHFBOE4FDUJPO 
QBHF

Preparing Drive Bush

4.1 IQ10 to IQ35


Thrust Base Types A and Z

6OTDSFXUIFCFBSJOHTUPQGSPNUIF
 ESJWFCVTI4MJEFUIFCFBSJOHPGGUIF
 ESJWFCVTI,FFQUIFESJWFCVTIBOE
 TUPQSJOHJOBTBGFDMFBOQMBDF

Removal of Drive Bush for


Machining

 'PSBMMTJ[FTFOTVSFUIFESJWFCVTI
male thread (stop ring) is not
EBNBHFEEVSJOHNBDIJOJOH'PSTJ[FT
*2 *2*2 FOTVSFUIF0SJOH
 MPDBUFEJOUIFESJWFCVTIJTOPU
EBNBHFEEVSJOHNBDIJOJOH.BDIJOF
 ESJWFCVTIUPTVJUUIFWBMWFTUFN 
 BMMPXJOHHFOFSPVTDMFBSBODFPOUIF
 TDSFXUISFBEGPSSJTJOHTUFNWBMWFT

Fig. 4.1 Components of Type A


Thrust Base

5VSOBDUVBUPSPOUPJUTTJEF SFNPWFUIF
UXPDBQIFBEFETDSFXTIPMEJOHCBTF
QMBUFPOUPUISVTUCBTF QVMMPVUUIF
ESJWFCVTIDPNQMFUFXJUIJUTCFBSJOH
BTTFNCMZ
#FGPSFNBDIJOJOHUIFESJWFCVTIUIF
UISVTUCFBSJOHNVTUCFSFNPWFE
*2 *2BOE*2BDUVBUPSTIBWFB
sealed thrust bearing located on the
ESJWFCVTIBOESFUBJOFECZUIFTUFFM

BTTFNCMZXPSLJOHMPPTF BTTIPXOJO
'JH3FGFSUPUIFUBCMFCFMPXGPS
SFRVJSFEUJHIUFOJOHUPSRVFT

Socket set Allen key Torque Torque


screw size bit size
Nm
lbs/ft


.

.





.

.





Re-assembly

CFBSJOHTUPQSJOH5IFCFBSJOHTUPQSJOH
JTMPDLFEXJUIPOFTPDLFUTFUTDSFX
Fig. 4 Bronze Drive Bush Fitted into
Thrust Taking Base





*2 *2BOE*2IBWFBUISVTUSBDF
CBMMCFBSJOHXJUIJOUIFTUFFMCFBSJOH
IPVTJOH MPDBUFEPOUIFESJWFCVTI
BOESFUBJOFECZUIFTUFFMCFBSJOHTUPQ
SJOH5IFCFBSJOHJTTFBMFEXJUIJOJUT
IPVTJOHCZ0SJOHTMPDBUFEPOUIFESJWF
CVTIBOEPOUIFCFBSJOHTUPQSJOH5IF
CFBSJOHTUPQSJOHJTMPDLFEXJUIUXP
TPDLFUTFUTDSFXT
 -PDBUFBOEMPPTFOUIFMPDLJOHTPDLFU
 TFUTDSFX T
JOUIFCFBSJOHTUPQSJOH

 3FNPWFBMMTXBSGGSPNUIFESJWF
 CVTI FOTVSJOHUIF0SJOHTPOUIF
 ESJWFCVTIBOECFBSJOHTUPQSJOH
 XIFSFGJUUFE
BSFVOEBNBHFE DMFBO
 BOEHSFBTFE
 4MJEFUIFCFBSJOHBTTFNCMZPOUPUIF
 ESJWFCVTIBOEFOTVSFJUJTGJUUFE
 EPXOUPUIFESJWFCVTITIPVMEFS
 4DSFXUIFTUPQSJOHXJUIUIFMPDLJOH
 TPDLFUTFUTDSFX T
VQQFSNPTUPOUP
 UIFESJWFCVTIVOUJMJUDPNFTUPB
 TUPQoIBOEUJHIUBOEMPDLXJUIUIF
 MPDLJOHTPDLFUTFUTDSFXT5IF
 MPDLJOHTPDLFUTFUTDSFXTNVTUCF
 EPOFVQUJHIUUPQSFWFOUUIF

Fig. 4.2
 3FGJUUIFESJWFCVTIBTTFNCMZJOUP
 UIFCBTFDBTUJOHPOUIFBDUVBUPS 
 FOTVSJOHUIBUUIFTMPUTJOUIFESJWF
 CVTIBSFMPDBUFEJOUPUIFESJWFEPHT
 PGUIFIPMMPXPVUQVUTIBGU
 3FGJUUIFCBTFQMBUFBOETFDVSFXJUI
 DBQIFBEFETDSFXT

4.2 IQ10 to IQ35


Non-Thrust Base Type B
6OEPUIFGPVSTFUTDSFXTTFDVSJOHUIF
CBTFQMBUFUPUIFHFBSDBTFBOESFNPWF
UIFCBTFQMBUF
5IFESJWFCVTIBOEJUTSFUBJOJOHDMJQDBO
OPXCFTFFO

Types B3 and B4 removal:


SFGFSUP'JH

6TJOHFYUFSOBMDJSDMJQQMJFST FYQBOEUIF
DJSDMJQXIJMFQVMMJOHPOUIFESJWFCVTI
5IFESJWFCVTIXJMMEFUBDIGSPNUIF
BDUVBUPSDFOUSFDPMVNOXJUIUIFDJSDMJQ
SFUBJOFEJOJUTHSPPWF

Fig. 4.4

Type B1

Fig. 4.5 Locating Set Screw

3FGFSUP'JH

5IFQSPDFEVSFGPSSFNPWBMBOESFGJUUJOH
PGUIF#ESJWFCVTIJTUIFBOETBNF
BTGPS#BOE# )PXFWFSUIFDJSDMJQJT
SFQMBDFEXJUIBDVTUPNTQSJOHDMJQ5IF
spring clip operates in the same manner
BTUIF##DJSDMJQCVUJTFYQBOEFE
VTJOHMPOHOPTFQMJFST

-PPTFOTFUTDSFXBOEVOTDSFXSFUBJOFS
VTJOHIBNNFSBOEQVODI3FNPWF
ESJWFCVTIBOENBDIJOFUPTVJUWBMWF
TUFNPSHFBSCPYJOQVUTIBGU

Fig. 4.7 Type A Drive Bush


*GUIFBDUVBUPSIBTBUZQF"ESJWFCVTI
'JH
UIJTDBOCFGJUUFEJOQPTJUJPO
PSUPTVJUUIFQPTJUJPOPGUIFWBMWF
NPVOUJOHGMBOHF

"MMPXHFOFSPVTDMFBSBODFPOTDSFX
UISFBEGPSSJTJOHTUFNWBMWFT

4.3 IQ40 to IQ95


Thrust Base Types A and Z
Removal of Drive Bush for
Machining
&OHBHFiIBOEwBOEUVSOIBOEXIFFM
VOUJMSFUBJOFSTFUTDSFXJTWJTJCMFUISPVHI
IPMFJOBDUVBUPSCBTF

Fig. 4.8 Type A Drive Bush in


Position 1

Fig. 4.3
Fig. 4.6 Removal of Retainer

52

Fig. 4.9 Type A Drive Bush in


Position 2
*GUIFBDUVBUPSIBTBUZQF;ESJWFCVTI
'JH
UIJTDBOPOMZCFGJUUFECFMPX
UIFBDUVBUPSCBTF 'JH


Fig. 4.11 Type Z3 Drive Bush in


Position 3
Fig. 4.13 B3/B4 Drive Bush

Re-Assembly
)BWJOHDPOGJSNFEUIFQPTJUJPOSFRVJSFE 
JOTFSUUIFNBDIJOFEESJWFCVTIFOTVSJOH
that the actuator output shaft dogs
BSFJOGVMMFOHBHFNFOUXJUIUIFCVTI
'JUESJWFCVTISFUBJOFSTFDVSFMZ UVSOJOH
DMPDLXJTFVOUJMGVMMZUJHIUFOFEVTJOH
IBNNFSBOEQVODI3PUBUFCZIBOE
XIFFMUPBMJHOSFUBJOFSTFUTDSFXXJUI
hole in the side of base and tighten to
/NMCTGU

4.4 IQ40 to IQ95


Non-Thrust Base Type B

Types B3 and B4
*EFOUJDBMESJWFCVTIFTTFDVSFECZDBQ
IFBEFETDSFXT
B3 is supplied pre-machined to ISO
TUBOEBSE
B4 is supplied blank and must be
machined to suit the input shaft of the
HFBSCPYPSWBMWFUIBUJUXJMMESJWF

Type B1
Fig. 4.10 Type Z3 Drive Bush

Fig. 4.12 Tightening Retainer Set


Screw

0VUQVUTIBGUCPSFEBOELFZFEUP*40
TUBOEBSE5IFSFJTOPESJWFCVTI
UPNBDIJOF

Fig. 4.14 B3/B4 Drive Bush in Situ

10

Mounting the Actuator

Refer to Weights and Measures page 78 for actuator weight.


&OTVSFUIFWBMWFJTTFDVSFCFGPSFGJUUJOHUIFBDUVBUPSBTUIFDPNCJOBUJPONBZCFUPQ
IFBWZBOEUIFSFGPSFVOTUBCMF
*GJUJTOFDFTTBSZUPMJGUUIFBDUVBUPSVTJOHNFDIBOJDBMMJGUJOHFRVJQNFOUDFSUJGJFE
TMJOHTTIPVMECFBUUBDIFEBTJOEJDBUFEJO'JHGPSWFSUJDBMWBMWFTIBGUTBOE'JH
GPSIPSJ[POUBMTIBGUT
"UBMMUJNFTUSBJOFEBOEFYQFSJFODFEQFSTPOOFMTIPVMEFOTVSFTBGFMJGUJOH 
QBSUJDVMBSMZXIFONPVOUJOHBDUVBUPST

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
NVTUCFGJUUFEUPUIFWBMWF

Fig. 5

"DUVBUPSUPWBMWFGJYJOHNVTUDPOGPSNUP.BUFSJBM4QFDJGJDBUJPO*40$MBTT ZJFME
TUSFOHUI/TRNN

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

Fig. 5.1

53

11

5.1 Rising Stem Valves


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

'JUUIFNBDIJOFEESJWFCVTIJOUPUIF
UISVTUCBTFBTQSFWJPVTMZEFTDSJCFE 
MPXFSUIFBDUVBUPSPOUPUIFUISFBEFE
WBMWFTUFN FOHBHFiIBOEwBOEXJOE
UIFIBOEXIFFMJOUIFPQFOJOHEJSFDUJPO
UPFOHBHFUIFESJWFCVTIPOUPUIF
TUFN$POUJOVFXJOEJOHVOUJMUIF
BDUVBUPSJTGJSNMZEPXOPOUIFWBMWF
GMBOHF8JOEUXPGVSUIFSUVSOT GJU
TFDVSJOHCPMUTBOEUJHIUFOGVMMZ

b) Fitting Thrust Base to Valve


Actuator Sizes 10 to 35 only

Fig. 5.2

'JUUIFNBDIJOFEESJWFCVTIJOUPUIF
UISVTUCBTFBTQSFWJPVTMZEFTDSJCFE
3FNPWFUIFUISVTUCBTFGSPNUIF
BDUVBUPS QMBDFJUPOUIFUISFBEFE
WBMWFTUFNXJUIUIFTMPUUFEFOEPGUIF
ESJWFCVTIVQQFSNPTUBOEUVSOJUJO
the opening direction to engage the
UISFBE$POUJOVFUVSOJOHVOUJMUIFCBTF
JTQPTJUJPOFEPOUPUIFWBMWFGMBOHF'JU
securing bolts but do not tighten at
UIJTTUBHF-PXFSUIFBDUVBUPSPOUPUIF
thrust base and rotate the complete
BDUVBUPSVOUJMUIFESJWFEPHTPOUIF
actuator output shaft engage into the
ESJWFCVTI"DUVBUPSGMBOHFTIPVMEOPX
CFGMVTIXJUICBTFGMBOHF

Torque
lbs/ft

Imperial Size

Nm

)FY



)FY





)FY





)FY






)FY



)FY



 

)FY



 

Fig. 5.3

)FY



 

$POUJOVFUPUVSOBDUVBUPSVOUJMGJYJOH
IPMFTBMJHO6TJOHCPMUTTVQQMJFEGJY
BDUVBUPSUPUISVTUCBTFBOEUJHIUFOEPXO
UPUIFSFRVJSFEUPSRVF see table A
0QFOWBMWFCZUXPUVSOTBOEGJSNMZ
UJHIUFOEPXOGJYJOHTPOUPWBMWFGMBOHF
UPUIFSFRVJSFEUPSRVF see table B

)FY



 

)FY



 

Size

Torque ( +
10%)
Nm
lbs/ft

Metric Size

Torque
Nm
lbs/ft

.)FY



.)FY






.)FY





.)FY





.)FY





.)FY



 

 .)FY)FBE





.)FY



 

.)FY)FBE





.)FY



 

Table A

Table B

12

5.2 Valve with Gearbox


Side Mounting
Check that the mounting flange is at
SJHIUBOHMFTUPUIFJOQVUTIBGU BOE
UIBUUIFESJWFCVTIGJUTUIFTIBGUBOE
LFZXJUIBEFRVBUFBYJBMFOHBHFNFOU
&OHBHFiIBOEw PGGFSVQBDUVBUPSUP
UIFJOQVUTIBGUBOEUVSOIBOEXIFFM
UPBMJHOLFZXBZBOELFZ5JHIUFO
NPVOUJOHCPMUT

5.3 Non-Rising Stem Valves


Top Mounting
5SFBUBTGPSTJEFNPVOUJOHFYDFQUUIBU
XIFOUISVTUJTUBLFOJOUIFBDUVBUPS 
BUISVTUOVUNVTUCFGJUUFEBCPWFUIF
ESJWFCVTIBOETFDVSFMZUJHIUFOFE

5.4 Handwheel Sealing


Ensure that sealing plug in centre of
IBOEXIFFM PSTQJOEMFDPWFSUVCF
EFQFOEJOHPOXIJDIJTGJUUFE
JTTFBMFE
XJUI15'&UBQFBOEGVMMZUJHIUFOFE 
ensuring that moisture does not
QBTTEPXOUIFDFOUSFDPMVNOPGUIF
BDUVBUPS

5.5 IQM Modulating Actuators

5.6 IQML Linear Drive Unit

5IF*2.SBOHFPGBDUVBUPSTBSFTVJUBCMF
GPSNPEVMBUJOHDPOUSPMEVUZPGVQUP
TUBSUTQFSIPVSJOBDDPSEBODFXJUI
*&$UP4

$POTJTUTPGBMFBETDSFXBTTFNCMZ
arrangement attached to the base
PGUIFBDUVBUPSJOPSEFSUPQSPWJEFB
MJOFBSPVUQVUTUSPLFCFUXFFONN
(38 in) minimum and 120mm (434 in)
NBYJNVN

*2.BDUVBUPSTIBWFBEZOBNJDCSBLJOH
GBDJMJUZBTTUBOEBSE*GNFDIBOJDBM
PWFSSVOPGUIFBDUVBUPSBOEWBMWFQSPWF
UPCFFYDFTTJWFGPSBDDVSBUFDPOUSPM UIF
CSBLFDBOCFFOBCMFECZGJUUJOHBMJOLUP
the actuator terminal block as indicated
CZUIFXJSJOHEJBHSBN8JUIEZOBNJD
CSBLJOHFOBCMFE NPUPSIFBUJOHFGGFDUT
increase and therefore the number
of actuator starts should be reduced
UPQSFWFOUNPUPSUIFSNPTUBUUSJQQJOH
(refer to publication E110E for more
information)

5IF*2.-DBOCFTVQQMJFEXJUIPS
XJUIPVUBZPLFNPVOUJOHBEBQUPS
This adaptor consists of four pillars and
BCBTFGMBOHFUPTVJUUIFWBMWF

$PNNJTTJPOJOHPG*2.SBOHFBDUVBUPST
JTJEFOUJDBMUPUIFTUBOEBSE*2(refer to
Sections 7, 8 and 9 commencing on
page 16)

Fig. 5.5 IQML without Yoke

Fig. 5.4 IQML with Yoke

54

13

5.7 IQML Adjusting Linear Stroke


8JUIBDUVBUPSTFDVSFMZGJUUFEUPWBMWF 
CVUXJUIUIFMJOFBSESJWFEJTDPOOFDUFE 
FOTVSFWBMWFJTBUJUTGVMMZDMPTFE EPXO

QPTJUJPO
3FNPWFDPWFSUVCFGSPNBDUVBUPS
IBOEXIFFM MPDBUFUIFEPXOTUPQ
BEKVTUNFOUPOUIFMJOFBSESJWFVOJUBOE
XJUIUXPTQBOOFSTMPPTFOUIFMPDLOVU 
SVOUIFMPDLOVUBOEUVCVMBSEPXOTUPQ
UPUIFFOEPGUIFUISFBE

5VSOUIFUVCVMBSEPXOTUPQDMPDLXJTF
into the actuator until it comes to a
NFDIBOJDBMTUPQ*GUIFWBMWFNVTUDMPTF
POUPJUTTFBUCZi50326&"$5*0/w
UIFOCBDLPGG BOUJDMPDLXJTF
UIF
EPXOTUPQCZPOFUIJSEPGPOFUVSO
FRVJWBMFOUUPNN
3VOUIFMPDLOVU
EPXOPOUPUIFUVCVMBSEPXOTUPQBOE
UJHIUFOXJUIUXPTQBOOFST5IFSFJTOP
iVQTUPQw PQFO
POUIFMJOFBSESJWF
VOJU UIFNFDIBOJDBMTUPQJOUIFWBMWF
XJMMHJWFUIJTQPTJUJPO3FGJUUIFUPQ
DPWFSUVCFUPUIFIBOEXIFFMVTJOH15'&
UBQFUPTFBMUIFUISFBE
5IFMJOFBSESJWFVOJUJTQSFQBDLFEXJUI
FYUSFNFQSFTTVSFNVMUJQVSQPTFHSFBTF
.6-5*4.4 VTFUIJTPSBOFRVJWBMFOU
IJHIUFNQFSBUVSFCFBSJOHHSFBTF
A grease nipple is situated in the base
of the actuator to enable lubrication of
UIFMFBETDSFX1FSJPEJDBMMZ EFQFOEJOH
POVTBHFBOEUFNQFSBUVSF BQQMZUXP
QVNQTPGBHSFBTFHVO

Fig. 5.6 Down Stop two Spanners


5VSOUIFBDUVBUPSIBOEXIFFMDMPDLXJTF 
MJOFBSESJWFXJMMNPWFEPXOUPXBSET
UIFWBMWFTQJOEMF DPVQMFMJOFBSESJWFUP
WBMWFTQJOEMF

14

Cable Connections

WARNING:
Ensure all power supplies
are isolated before removing
actuator covers.
$IFDLUIBUUIFTVQQMZWPMUBHFBHSFFT
XJUIUIBUTUBNQFEPOBDUVBUPS
OBNFQMBUF
"TXJUDIPSDJSDVJUCSFBLFSNVTUCF
JODMVEFEJOUIFXJSJOHJOTUBMMBUJPOPG
UIFBDUVBUPS5IFTXJUDIPSDJSDVJU
breaker shall be mounted as close
to the actuator as possible and shall
be marked to indicate that it is the
EJTDPOOFDUJOHEFWJDFGPSUIBUQBSUJDVMBS
BDUVBUPS5IFBDUVBUPSNVTUCF
QSPUFDUFEXJUIPWFSDVSSFOUQSPUFDUJPO
EFWJDFTSBUFEJOBDDPSEBODFXJUI
3PUPSLQVCMJDBUJPO/P&&&MFDUSJD
NPUPSQFSGPSNBODFEBUBGPS*2SBOHF
BDUVBUPST

6.1 Earth/Ground Connections


"MVHXJUIBNNEJBNFUFSIPMFJT
DBTUBEKBDFOUUPUIFDPOEVJUFOUSJFTGPS
BUUBDINFOUPGBOFYUFSOBMQSPUFDUJWF
FBSUIJOHTUSBQCZBOVUBOECPMU"O
JOUFSOBMFBSUIUFSNJOBMJTBMTPQSPWJEFE 
IPXFWFSJUNVTUOPUCFVTFEBMPOFBT
UIFQSPUFDUJWF&BSUI$POOFDUJPO

6.2 Removing Terminal Cover


6TJOHBNN"MMFOLFZMPPTFOUIFGPVS
DBQUJWFTDSFXTFWFOMZ%POPUBUUFNQU
UPMFWFSPGGUIFDPWFSXJUIBTDSFXESJWFS
BTUIJTXJMMEBNBHFUIFi0wSJOHTFBM
BOENBZEBNBHFUIFGMBNFQBUIPOB
DFSUJGJFEVOJU

Actuators containing a Setting Tool or


Setting Tool Pro fitted to the inside of
UIFUFSNJOBMDPNQBSUNFOUDPWFSBSF
JEFOUJGJFEXJUIBTFMGBEIFTJWFZFMMPX
label on the outside of the terminal
DPNQBSUNFOUDPWFS
5IFXJSJOHDPEFDBSEGJYFEJOUIFDPWFS
is particular to each actuator and must
OPUCFJOUFSDIBOHFEXJUIBOZPUIFS
BDUVBUPS*GJOEPVCUDIFDLUIFTFSJBM
OVNCFSPOUIFDPEFDBSEXJUIUIBUPG
UIFBDUVBUPS

Fig. 6.2 - Actuator containing Rotork


Setting Tool Pro.

A plastic bag in the terminal


compartment contains:
t5FSNJOBMTDSFXTBOEXBTIFST
t4QBSFDPWFSi0wSJOHTFBM
t8JSJOHEJBHSBN
t*OTUSVDUJPOCPPL

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 earthphase systems, where phase to
earth voltages in excess of 600V
a.c. could exist.

Fig. 6.3

6.3 Cable Entry


Fig. 6
Fig. 6.1 - Actuator containing Rotork
Setting Tool.

55

0OMZBQQSPQSJBUFDFSUJGJFE&YQMPTJPO
1SPPGFOUSZSFEVDFST HMBOETPSDPOEVJU
NBZCFVTFEJOIB[BSEPVTMPDBUJPOT

15

3FNPWFSFEQMBTUJDUSBOTJUQMVHT.BLF
cable entries appropriate to the cable
UZQFBOETJ[F&OTVSFUIBUUISFBEFE
BEBQUPST DBCMFHMBOETPSDPOEVJU
BSFUJHIUBOEGVMMZXBUFSQSPPG4FBM
VOVTFEDBCMFFOUSJFTXJUIBTUFFMPS
CSBTTUISFBEFEQMVH*OIB[BSEPVTBSFBT
BOBQQSPQSJBUFMZDFSUJGJFEUISFBEFE
CMBOLJOHQMVHNVTUCFVTFE

6.5 Replacing Terminal Cover

Heading

&OTVSFDPWFSi0wSJOHTFBMBOETQJHPU
KPJOUBSFJOHPPEDPOEJUJPOBOEMJHIUMZ
HSFBTFECFGPSFSFGJUUJOHDPWFS

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 SOLO
TEMPORANEI. PER UNA PROTEZIONE PERMANENTE PREGO SOSTITUIRLI CON
APPOSITI TAPPI METALLICI.

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.

ATENCION: LOS TAPONES ROJOS DE PLASTICO EN LAS ENTRADAS DE CABLE


SON UNICAMENTE PARA TRANSPORTE. PARA PROTECCION PERMANENTE
COLOCAR TAPONES METALICOS APROPIADOS.
ACHTUNG: DIE ROTEN PLASTIKSTOPFEN SIND NUR FR DEN TRANSPORT
GEEIGNET. FR DAVERHAFTEN SCHUTZ SIND DIESE GEGEN GEEIGNETE
BLINDSTOPFEN AUSZTAUSCHEN.
ATTENTION: LES BOUCHONS PLASTIQUES ASSURENT UNE PROTECTION
TEMPORAIRE. POUR UNE PROTECTION DEFINITIVE UTILISER DES BOUCHONS
METALLIQUES.

3FGFSUPUIFXJSJOHEJBHSBNJOTJEFUIF
UFSNJOBMDPWFSUPJEFOUJGZGVODUJPOTPG
UFSNJOBMT$IFDLUIBUTVQQMZWPMUBHF
is the same as that marked on the
BDUVBUPSOBNFQMBUF
3FNPWFQPXFSUFSNJOBMTDSFFO
#FHJOCZDPOOFDUJOHUIFTFDBCMFTBOE
SFQMBDFTDSFFO
When all connections are made ensure
XJSJOHEJBHSBNJTSFQMBDFEJOUIF
UFSNJOBMDPNQBSUNFOU

16

Commissioning

7.1 The Setting Procedure

2.

Configuration Settings

5IF3PUPSL*2SBOHFPGBDUVBUPSTJTUIF
first that enables commissioning to be
DBSSJFEPVUXJUIPVUSFNPWJOHDPWFST

4FUUJOHTDPWFSJOHUIFDPOUSPM 
indication and optional
FRVJQNFOUGVODUJPOT

4FUUJOHUPSRVF MJNJUBOEPUIFSGVODUJPOT
JTBDIJFWFECZVTJOHUIF*OGSB3FE
4FUUJOH5PPM5IF4FUUJOH5PPMJTDFSUJGJFE
*OUSJOTJDBMMZ4BGFUPBMMPXDPNNJTTJPOJOH
JOIB[BSEPVTBSFBT
All the commissioning functions are
TUPSFEJOOPOWPMBUJMFNFNPSZJOUIF
BDUVBUPS5IF4FUUJOH5PPMFOBCMFTUIF
VTFSUPWJFXBMMUIFGVODUJPOTJOUVSO
WJBUIFBDUVBUPSEJTQMBZXJOEPX"T
FBDIGVODUJPOJTWJFXFEJUTTFUUJOHDBO
CFDIFDLFEBOE JGSFRVJSFE DIBOHFE
XJUIJOUIFCPVOETPGUIBUGVODUJPO
$PNNJTTJPOJOHNBZCFDBSSJFEPVUXJUI
NBJOQPXFSTXJUDIFEPOPSPGG3FGFS
UPQBHFGPS1PXFS0GG4FUUJOH
5IFTFUUJOHQSPDFEVSFJTEJWJEFEJOUP
UXPTUBHFT

1.

Basic Settings





4FUUJOHTGPSFOEPGUSBWFMMJNJU
BDUJPOT UPSRVFWBMVFT MJNJU
QPTJUJPOTFUD

Actuator Display
Position Display


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
XJUIDBVUJPOBTTFUUJOHTTFMFDUFEBGUFS
NBOVGBDUVSFNBZCFFTTFOUJBMGPSUIF
TBGFPQFSBUJPOPGUIFWBMWFBOEPSQMBOU

Torque and Position


Password
Crossroad









50

m


50
5PSRVF

5IJTNBZCFBOPQFOPSDMPTFETZNCPM
PSBQFSDFOUBHFPQFOWBMVF
3FGFSUP4FDUJPO

P?

cr

m
m

PC

Ir

tP

Basic Settings

Configuration Settings

%JSFDUJPO
Limit Actions
5PSRVF7BMVFT
-JNJU1PTJUJPOT



*OEJDBUJPO$POUBDUT
Control Mode
0QUJPOT
)FMQ4DSFFOT
%FGBVMUT

Note: The Basic Settings must be commissioned first.

56

17

7.2 The Setting Tool (old version)

Specification
Enclosure

IP67

$FSUJGJDBUJPO





&&YJB**$5 JOUSJOTJDBMMZTBGF

'. */54"'& $MBTT***%JW(SPVQT"#$%&'( 5"


$4" &YJB $MBTT* **%JW(SPVQT"#$%

1PXFSTVQQMZ

7#BUUFSZ TVQQMJFEBOEGJUUFE

0QFSBUJOHSBOHF N GSPNBDUVBUPSEJTQMBZXJOEPX

Name

m ,FZ 

3
5

Instruction
%JTQMBZOFYUGVODUJPOEPXO

k ,FZ 

%JTQMBZOFYUGVODUJPOBDSPTT

 - ,FZ

%FDSFBTFDIBOHFEJTQMBZFEGVODUJPOTWBMVFPSPQUJPOTFUUJOH

Fig. 7.1 The Setting Tool

+ ,FZ

*ODSFBTFDIBOHFEJTQMBZFEGVODUJPOTWBMVFPSPQUJPOTFUUJOH

Setting Tool Battery Replacement

&OUFSEJTQMBZFEWBMVFPSPQUJPOTFUUJOH

#BUUFSZTUBUVTDBOCFDIFDLFECZMPPLJOHBUUIF*OGSBSFEUSBOTNJUUFSXJOEPXXIJMF
EFQSFTTJOHBOZ4FUUJOH5PPMCVUUPO"GMBTIJOHSFEJOEJDBUPSTIPVMECFTFFO

,FZ



1SFTTJOHUIFUXPBSSPXLFZTUPHFUIFSSFUVSOTUIFBDUVBUPSEJTQMBZUPUIFQPTJUJPO
indication mode

Infra-red local operation XIFOFOBCMFE

,FZ



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.

4UPQBDUVBUPS



,FZ

0QFOBDUVBUPS



,FZ

$MPTFBDUVBUPS

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.

8IFOBCVUUPOJTEFQSFTTFEUIF4FUUJOH5PPMUSBOTNJUTUIFSFMFWBOUJOTUSVDUJPO
UPUIFBDUVBUPSCZJOGSBSFEQVMTFTBOENVTUUIFSFGPSFCFEJSFDUMZJOGSPOUPGUIF
BDUVBUPSJOEJDBUPSXJOEPXBOEBUBEJTUBODFOPHSFBUFSUIBON

*OGSBSFE5SBOTNJUUFS8JOEPX

18

Commissioning continued

7.2 The Setting Tool Pro (new version)


Specification

12

Enclosure
IP54
This Setting Tool ProIBTCFFOCVJMUJOBDDPSEBODFXJUIUIFGPMMPXJOHTUBOEBSET


64")B[BSEPVT"SFB


'BDUPSZ.VUVBM&YQMPTJPO1SPPGUP/&$"SUJDMF


*OUSJOTJDBMMZ4BGF $MBTT %JW (SPVQT" # $% 5


$BOBEB)B[BSEPVT"SFB
$4"&YJB*OUSJOTJDBMMZ4BGF $MBTT %JW (SPVQT" # $% 5
Temperature
Tamb = -30C to 50C
1PXFSTVQQMZ
Y7#BUUFSJFT TVQQMJFEBOEGJUUFE

0QFSBUJOHSBOHF N GSPNBDUVBUPSEJTQMBZXJOEPX

6
7

Name

Instruction

i ,FZ

%JTQMBZQSFWJPVTGVODUJPOVQ

k ,FZ 

%JTQMBZOFYUGVODUJPOBDSPTT

o ,FZ

%JTQMBZQSFWJPVTGVODUJPOBDSPTT



 - ,FZ

%FDSFBTFDIBOHFEJTQMBZFEGVODUJPOTWBMVFPSPQUJPOTFUUJOH



,FZ

0QFOBDUVBUPS

+ ,FZ

*ODSFBTFDIBOHFEJTQMBZFEGVODUJPOTWBMVFPSPQUJPOTFUUJOH



,FZ

$MPTFBDUVBUPS

m ,FZ

*OJUJBUFEPXOMPBEVQMPBENPEF

*OGSBSFE5SBOTNJUUFS8JOEPX

m ,FZ 



,FZ

%JTQMBZOFYUGVODUJPOEPXO

11

Fig. 7.2 The Setting Tool Pro

Infra-red local operation XIFOFOBCMFE

&OUFSEJTQMBZFEWBMVFPSPQUJPOTFUUJOH

1SFTTJOHUIFTFUXPBSSPXLFZTUPHFUIFSSFUVSOTUIFBDUVBUPSEJTQMBZUPUIF
position indication mode

57

,FZ

4UPQBDUVBUPS

10

19

Download / Upload Function


5IJTOFXGFBUVSFIBTCFFOJOUSPEVDFE
XJUIUIFOFX3PUPSL4FUUJOH5PPM
Pro*UBMMPXTUIFVTFSUPEPXOMPBE
EBUBMPHHFSGJMFTBOEEPXOMPBEVQMPBE
DPOGJHVSBUJPOGJMFT5IFOFXUPPMJT
XFBUIFSQSPPGBOEJOUSJOTJDBMMZTBGF
BOETPJUDBOCFVTFETBGFMZJOBMM
FOWJSPONFOUT'PSNPSFJOGPSNBUJPO
SFGFSUP4FDUJPO QBHF

Setting Tool Pro Battery


Replacement
#BUUFSZTUBUVTDBOCFDIFDLFECZMPPLJOH
BUUIF*OGSBSFEUSBOTNJUUFSXJOEPX
XIJMFEFQSFTTJOHBOZ4FUUJOH5PPMPro
CVUUPOFYDFQUUIFEPXOMPBECVUUPO"
GMBTIJOHSFEJOEJDBUPSTIPVMECFTFFO
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

No form of repair must be attempted


on the actuator Setting Tool Pro.

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.

When a button is depressed the


Setting Tool ProUSBOTNJUTUIFSFMFWBOU
JOTUSVDUJPOUPUIFBDUVBUPSCZJOGSBSFE
QVMTFTBOENVTUUIFSFGPSFCFEJSFDUMZJO
GSPOUPGUIFBDUVBUPSJOEJDBUPSXJOEPX
and at a distance no greater than
N

Display Set-Up Mode


The Setting Tool and Setting Tool Pro
BSSPXLFZTBSFVTFEUPBDDFTTBOE
OBWJHBUFUISPVHIUIFBDUVBUPSTFUVQ
QSPDFEVSFVTJOHUIFBDUVBUPSEJTQMBZ
&BDIBDUVBUPSGVODUJPOXJUIJUhTDVSSFOU
TFUUJOHJTSFQSFTFOUFEPOTDSFFOCZ
BDPNCJOBUJPOPGDPEFBOEUFYU5IF
4FUUJOH5PPMDIBOHFLFZT BOEo

BMMPXUIFVTFSUPWJFXUIFBWBJMBCMF
TFUUJOHPQUJPOT

Function
Code

Function

Setting
Code

Close Action
Close on Torque

Function
Code

Function

Setting
Option

Setting
Value

Open Torque
40%

Setting
Value

5IFFYBNQMFTPGEJTQMBZFEGVODUJPOT

Close Action [C2] and Open Torque [tO]


BSFTIPXOUPUIFSJHIU/PUFUIBUB
TFUUJOHPQUJPOPSWBMVFJTIJHIMJHIUFE
This instruction manual uses both code
BOEUFYUGPSEFTDSJQUJPO

20

Commissioning continued

7.3 Entering the Actuator


Setting Procedure
8JUIUIFBDUVBUPSTFDVSFMZNPVOUFE
POUIFWBMWF UIFNBJOTTVQQMZPOBOE
-PDBMDPOUSPMPS4UPQTFMFDUFE

PRESS THE m KEY.


5IFBDUVBUPSVQQFSEJTQMBZXJMMSFNBJO
UIFTBNFBOEUIFMPXFSEJTQMBZXJMM
DIBOHFUP5PSRVFWBMVF5IJTXJMMCF
SFQSFTFOUFECZ5PSRVF99BOEB
CBSHSBQI(For instantaneous torque
& position monitoring, refer to Section
10, page 66.)

PRESS THE m KEY.

7.4 Setting Mode Password

7.5 New Password [PC]

7.6 Checking Mode

5PFOBCMFTFUUJOHBOEBEKVTUNFOUPGUIF
BDUVBUPSGVODUJPOTUIFDPSSFDUQBTTXPSE
NVTUCFFOUFSFE5IFGBDUPSZTFU EFGBVMU

QBTTXPSEJT[ld]*GUIFBDUVBUPSIBT
QSFWJPVTMZCFFOTFUXJUIBTJUFQBTTXPSE
UIJTNVTUCFFOUFSFE

5PDPOGJHVSFBOFXQBTTXPSE UIF
BDUVBUPSNVTUCFJOTFUUJOHNPEFXJUI
UIFQBTTXPSEEJTQMBZoTFUUJOHNPEF
FOBCMFEoTIPXJOH

The actuator function settings can be


DIFDLFEXJUIPVUFOUFSJOHUIFDPSSFDU
QBTTXPSE5IFTFUUJOHTDBOPOMZCF
WJFXFEBOEOPUBMUFSFE5IFTFUUJOHCBST
XJMMOPUCFTFFO

Use the + or - LFZTUPTDSPMMUISPVHIUIF


BWBJMBCMFQBTTXPSETo'' IFYBEFDJNBM

8JUIUIFDPSSFDUQBTTXPSEEJTQMBZFEQSFTT
UIFFOUFSLFZ

5IFEJTQMBZXJMMDIBOHFUP[PC]6TJOHUIF
+ or -LFZTDSPMMUISPVHIUIFBWBJMBCMF
QBTTXPSETVOUJMUIFEFTJSFEQBTTXPSEJT
EJTQMBZFE

PRESS THE

KEY

PRESS THE

PRESS THE

KEY.

Once the procedure has been completed


JOUIFSFRVJSFENPEF
Change Password
IE Hex

Password Changed to [IE]


Enter Password
Password Correct

Enter Password
ID Hex

Password Display, Checking Mode

5XPiTFUUJOHwCBSTXJMMBQQFBSBOEXJMM
SFNBJOWJTJCMFPOFWFSZGVODUJPOEJTQMBZ
TDSFFO*OBEEJUJPO 1BTTXPSE$PSSFDU
XJMMCFEJTQMBZFEGPSTFDPOET

5IFBDUVBUPSEJTQMBZXJMMDIBOHFBOE
UIFQBTTXPSEQSPUFDUJPOEJTQMBZXJMM
CFTFFO

Enter Password
ID Hex

k KEY.

NOTE:5IFOFXQBTTXPSECFDPNFT
FGGFDUJWFUIFOFYUUJNFTFUUJOHNPEFJT
FOUFSFE

Default Password,
Setting Mode Enabled

The Actuator Function Settings


can be protected by the Use
of a Password

58

PRESS THE m KEY.


The procedure branch [Cr] (crossroad)
EJTQMBZDBOOPXCFTFFO(refer to Section
7.7 page 21).

21

7.7 Crossroad [Cr]

Basic Setup
Config Setup

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 Mode
Actuator functions as laid out in the
Basic and Configuration commissioning
TUBHFT DBOCFJOEJWJEVBMMZEJTQMBZFECZ
VTJOHUIF4FUUJOH5PPMBSSPXLFZT
The m BSSPXLFZXJMMBMXBZTEJTQMBZ
UIF'*345GVODUJPOPOUIFOFYUMFWFM
%08/XJUIJOUIFQSPDFEVSF
The k BSSPXLFZXJMMBMXBZTEJTQMBZ
UIF/&95GVODUJPOPOUIF4".&MFWFM
BOEXJMMXSBQBSPVOEUIFGVODUJPOTPO
UIFTBNFMFWFM
5IFBDUVBUPSEJTQMBZJOEJDBUPSMBNQTXJMM
DPOUJOVFUPJOEJDBUFWBMWFQPTJUJPOCVU
XJMMBMTPGMBTIEVSJOH*3DPNNVOJDBUJPO

or -LFZTXJMMDBVTFUIFTFUUJOHUPCF

In setting mode the Setting Tool +

7.9 Returning to
Valve Position Display

DIBOHFE*ODIFDLJOHNPEFUIFTFUUJOHT
DBOOPUCFBMUFSFE

5IFSFBSFGJWFXBZTPGSFUVSOJOHUPWBMWF
QPTJUJPOEJTQMBZ

*OTFUUJOHNPEF PODFEJTQMBZFE BOFX


setting can be entered into the actuator
key
NFNPSZCZpressing the
5IFTFUUJOHXJMMGMBTIPGGBOECBDLPO 
DPOGJSNJOHJUTTFMFDUJPO BOEStored 
XJMMCFEJTQMBZFEGPSTFDPOETJOUIF
UFYUEJTQMBZ

 "QQSPYJNBUFMZNJOVUFTBGUFSUIF
last Setting Tool operation the

EJTQMBZXJMMBVUPNBUJDBMMZSFUVSOUP

QPTJUJPOEJTQMBZ

TOP LEFT
PORTION


TOP RIGHT
PORTION

"DUVBUPSGVODUJPOTBSFEJTQMBZFEJO
code form in the top left portion of the
MJRVJEDSZTUBMEJTQMBZTDSFFO
5IFTFUUJOHGPSUIFEJTQMBZFEGVODUJPOJT
TIPXOJOUIFUPQSJHIUIBOEQPSUJPOPG
UIFTDSFFO%FQFOEJOHPOUIFBDUVBUPS
GVODUJPOEJTQMBZFE JUTTFUUJOHNBZCF
BOPQUJPOPSBWBMVF

Close Torque
40%

Function Setting
FH7BMVF

k BSSPXLFZT

 1SFTTUIFm BSSPXLFZVOUJMUIF



EJTQMBZSFUVSOTUPQPTJUJPO
 4FMFDU3FNPUFDPOUSPMVTJOHUIF

SFE-PDBM4UPQ3FNPUFTFMFDUPS



*GZPVIBWFUIFOFX4FUUJOH5PPM
ProUIFOZPVDBOVTFUIFiBSSPX
LFZUPSFUVSOUPQPTJUJPOEJTQMBZ

LOWER DISPLAY


'VODUJPO$MPTF5PSRVF
4FUUJOH7BMVF
Typical Actuator Function Display
Setting Mode Enabled

5FYUSFMBUJOHUPUIFGVODUJPOBOETFUUJOH
WBMVFTXJMMCFEJTQMBZFEJOUIFMPXFS
EJTQMBZ

'VODUJPOFH
U$5PSRVF$MPTF

 1SFTTUIFm and



UPHFUIFS

22

Commissioning
Basic Functions
ELECTRICAL OPERATION MUST
NOT TAKE PLACE UNTIL THE BASIC
SETTINGS HAVE BEEN MADE AND
CHECKED.
The actuators Basic Settings affect
UIFDPSSFDUPQFSBUJPOPGUIFWBMWFCZ
UIFBDUVBUPS*GUIFBDUVBUPSIBTCFFO
TVQQMJFEXJUIUIFWBMWF UIFWBMWFNBLFS
PSTVQQMJFSNBZIBWFBMSFBEZNBEF
UIFTFTFUUJOHT
This instruction assumes setting mode
has been entered (refer to section 7.4
page 20)

Viewing the Basic Settings


With the actuator mounted on the
WBMWF UIFQPXFSTVQQMZPOBOE-PDBM
PS4UPQDPOUSPMTFMFDUFE QPJOUUIF
Setting Tool at the actuator indicator
XJOEPXGSPNBEJTUBODFPGOPNPSF
UIBON#ZQSFTTJOHUIFm LFZ
BOE XIFOBQQSPQSJBUF UIFk LFZ 
JUJTQPTTJCMFUPNPWFUISPVHIUIF
QSPDFEVSF EJTQMBZJOHUIFWBSJPVT
GVODUJPOTBOEUIFJSTFUUJOHTBTTIPXO
JO'JH(refer to page 23)5IF
SJHIUIBOETJEFPG'JHFYQMBJOTUIF
GVODUJPOPGFBDI-$%EJTQMBZ
Fig. 8

59

Power Off Setting


*2BMMPXTTFUUJOHTUPCFWJFXFEBOE
TFUXJUIPVUNBJOQPXFS5PFOBCMFUIJT
GVODUJPO FOHBHFIBOEXIFFMESJWFBOE
SPUBUFVOUJMUIFPVUQVUESJWFNPWFT
(refer to page 3)5IF4FUUJOH5PPMDBO
OPXCFVTFE"TMPOHBTB4FUUJOH
5PPMLFZQSFTTUBLFTQMBDFXJUIJOUIF
TFDPOETUJNFPVUQFSJPE 1PXFS
0GG4FUUJOHXJMMSFNBJOFOBCMFE*GOP
infra-red Setting Tool communication
UBLFTQMBDFUIFEJTQMBZXJMMSFUVSOUP
JOEJDBUJOHQPTJUJPO5IFBDUVBUPSNVTU
UIFOCFPQFSBUFECZIBOEXIFFMUP
SFFOBCMF1PXFS0GG4FUUJOH

Settings and operation must


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

23

Viewing the Basic Settings

Function

Description

50

50

Torque and Position Display

5PSRVF

PC

Cr

Configuration

C1

C2

m
tC

m
LC

tO

LO

Ir

P?

REFER TO SECTION 7, COMMISSIONING

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

tP

C3

Password

m
Crossroad

k Password Change k IrDA k Torque Reference Profile


k Configuration Settings, refer to page 32.

Direction to Close

k Close Action k Open Action

Torque Value Closing

m
Limit Closed

50

BASIC SETTINGS CONTENTS


page
C1
C2
C3
tC
tO
LC
LO

k Torque Value Opening

k Limit Open

Position Display

Direction to Close
Close Action
Open Action
Torque Value Closing
Torque Value Opening
Set Limit Closed
Set Limit Open

24
25
26
27
28
29
29

Fig. 8.1 Basic Setting Displays

C1

24

Direction to Close

The actuator can be configured to be


DMPDLXJTFPSBOUJDMPDLXJTFUPDMPTF
.BOVBMMZPQFSBUFBDUVBUPSBOEWBMWF
UPFTUBCMJTIDPSSFDUDMPTJOHEJSFDUJPO
$POWFSTJPO)BOEXIFFMEJSFDUJPOMBCFMT
BSFBWBJMBCMF

50

PC

Ir

tP

cr

m
c1

m
tC

m
LC

c2

tO

LO

c3

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

[C] in the Setting Field Indicating


Clockwise to Close

5PSRVF

P?

PRESS THE

Close Direction
Clockwise

)BWJOHFOTVSFEUIBUUIFEJTQMBZ
corresponds to the established
closing direction

PRESS THE

50

Using the + or -LFZ EJTQMBZUIF


character conforming to correct closing
EJSFDUJPO

Close Direction
Anticlockwise

[A] in the Setting Field Indicating


Anti-clockwise to Close

50

60

k KEY.

C2

25

Close Action

The actuator can be configured to close


POUPSRVFGPSTFBUJOHWBMWFTBOEMJNJU
GPSOPOTFBUJOHWBMWFT

Using the + or -LFZ EJTQMBZUIF


SFRVJSFEPQUJPO

Refer to valve manufacturer


for recommended setting.
*OUIFBCTFODFPGWBMWFNBLFS
JOTUSVDUJPOTSFGFSUPUIFGPMMPXJOHUBCMF

50

m
50

Valve type

Close

Open

8FEHFHBUF
(MPCF

iUPSRVFw
iUPSRVFw

iMJNJUw
iMJNJUw

#VUUFSGMZ
Thru conduit
Ball
Plug
Sluice gate
Penstock
Parallel slide

iMJNJUw
limit
limit
limit
limit
limit
limit

iMJNJUw
limit
limit
limit
limit
limit
limit

5PSRVF

m
P?

PC

Ir

tP

cr

m
c1

m
tC

m
LC

c2

tO

LO

c3

Close Action
Close on Limit

[CL] in the Setting Field Indicating


Close on Limit - default setting.

Close Action
Close on Torque

)BWJOHTFMFDUFEUIFSFRVJSFEPQUJPO

PRESS THE

C3

26

Using the + or -LFZEJTQMBZUIF


SFRVJSFEPQUJPO

Refer to valve manufacturer


for recommended setting. In the
absence of valvemaker instructions
set Open Limit

50

NOTE:8IFOTFUUPPQFOPOUPSRVF 
UIFBDUVBUPSXJMMBQQMZUIFMFWFMPG
UPSRVFBTTFUGPS[tO] in back seating
UIFWBMWF(refer to [tO] page 28)

Open Action
Open on Limit

[OL] in the Setting Field Indicates


Open on Limit - defualt setting.

m
50
5PSRVF

PC

Ir

cr

m
c1

m
tC

m
LC

tP

Open Action
Open on Torque

[Ot] in the Setting Field Indicates


Open on Torque.

k KEY.

Open Action

The actuator can be configured to


PQFOPOUPSRVFGPSCBDLTFBUJOHWBMWFT
PSMJNJUGPSOPOCBDLTFBUJOHWBMWFT

P?

KEY

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

PRESS THE

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

[Ct] in the Setting Field Indicating


Close on Torque.

50

NOTE:8IFOTFUUPDMPTFPOUPSRVF 

c2

c3
PRESS THE

tO

LO

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI(stored) 
JOEJDBUJOHUIBUJUIBTCFFOTFU

PRESS THE

k KEY.

50

61

tC

27

Close Torque

5IFWBMVFPGUPSRVFBWBJMBCMFJOUIF
DMPTFEJSFDUJPODBOCFDPOGJHVSFE
Refer to valve manufacturer
for recommended value.
5IFDMPTJOHUPSRVFWBMVFDBOCFWBSJFE
CFUXFFOBOE3BUFE 
JO
JODSFNFOUT

50

m
50
5PSRVF

m
P?

PC

Ir

tP

c1

m
tC

m
LC

Close Torque
40%

If the actuator fails to


complete a closed valve operation
due to the set torque being
reached (Torque Trip CL "MBSN QBHF

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

cr

Using the + and -LFZT UIFEJTQMBZ


SFDPNNFOEFEWBMVF*OUIFBCTFODFPG
BSFDPNNFOEFEUPSRVFWBMVF USZBMPX
TFUUJOHBOEJODSFBTFVOUJMTBUJTGBDUPSZ
WBMWFPQFSBUJPOJTBDIJFWFE

40% of Rated Torque

Close Torque
99%

99% of Rated Torque

KEY.

5IFEJTQMBZFEWBMVFXJMMGMBTI(stored) 
JOEJDBUJOHUIBUJUIBTCFFOTFU

c2

tO

Close Torque
100%

4IPVMEUIFTFUMFWFMPGUPSRVFCF
EFWFMPQFEJODMPTJOH UIFBDUVBUPSXJMM
UPSRVFUSJQBOETUPQ

c3

PRESS THE

Rated Torque

k KEY.

NOTE:3BUFEUPSRVFJTRVPUFEPOUIF
BDUVBUPSOBNFQMBUF

LO

50

tO

28

Open Torque

5IFWBMVFPGUPSRVFBWBJMBCMFJOUIF
PQFOEJSFDUJPODBOCFDPOGJHVSFE
Refer to valve manufacturer
for recommended value.

BOOST SHOULD NOT BE


SELECTED WHEN THE ACTUATOR
HAS BEEN CONFIGURED TO OPEN
ON TORQUE (refer to [C3] page 26)

50

m
50

P?

PC

Ir

cr

m
c1

m
tC

m
LC

m
50

c2

tO

LO

c3

tP

NOTE:3BUFEUPSRVFJTRVPUFEPOUIF
BDUVBUPSOBNFQMBUF#PPTUUPSRVFJTBU
MFBTUPG3BUFEUPSRVF

PRESS THE

KEY.

5IFEJTQMBZFEWBMVFXJMMGMBTI(stored) 
JOEJDBUJOHUIBUJUIBTCFFOTFU

4IPVMEUIFTFUMFWFMPGUPSRVFCF
EFWFMPQFEJOPQFOJOH UIFBDUVBUPSXJMM
UPSRVFUSJQBOETUPQ

UNLESS BACK SEATING AT RATED


TORQUE IS ACCEPTABLE.

5PSRVF

5IFPQFOJOHUPSRVFWBMVFDBOCF
WBSJFECFUXFFOBOE3BUFE JO
JODSFNFOUT*OBEEJUJPOi#PPTUwDBO
CFDPOGJHVSFEXIFOOPPQFOUPSRVF
QSPUFDUJPOJTSFRVJSFE

Using the + and -LFZT EJTQMBZUIF


SFDPNNFOEFEUPSRVFWBMVF

PRESS THE

In the absence of a recommended


UPSRVFWBMVF USZBMPXTFUUJOHBOE
JODSFBTFVOUJMTBUJTGBDUPSZWBMWF
PQFSBUJPOJTBDIJFWFE
If the actuator fails to
complete a open valve operation
due to the set torque being
reached (Torque Trip OP "MBSN QBHF
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.

62

m KEY.

Open Torque
40%

40%

Open Torque
99%

99%

Open Torque
100%

Rated

Open Torque
Boost

Boost
*ODIFDLJOHNPEF POQSFTTJOHUIFm
LFZBGUFSSFWJFXJOHPQFOUPSRVFTFUUJOH 
UIFEJTQMBZXJMMSFWFSUUPWBMWFQPTJUJPO

LC

LO

Set Limit Closed

NOTE: It is possible to set the Open


Limit Position [LO]GJSTU

50

With [LC] displayed

50
5PSRVF

Set Close Limit


Move to Close

50

P?

5PSRVF

P?

PC

Ir

c1

m
tC

m
LC

Move valve manually to the closed


position. Allow for overrun by
winding actuator output open by
1/2 to 1 turn.

PRESS THE

tC

KEY.

c2

tO

5IFUXPCBSTXJMMGMBTI TUPSFE
and the
DMPTFEJOEJDBUPSMBNQXJMMJMMVNJOBUF 
indicating closed limit position has been
TFU

LO

PRESS THE

c3

k KEY.

To check closed limit position hand


XJOEWBMWFPQFOVOUJMUIFBNCFSMBNQ
JMMVNJOBUFT8JOEWBMWFCBDLDMPTFE
VOUJMUIFDMPTFEMBNQJMMVNJOBUFT

50

PC

Ir

c1

m
m
LC

Set Open Limit


Move to Open

tP

Limit Open

cr

Limit Closed

tP

cr

With [LO] displayed

50

29

Set Limit Open

c2

tO

LO

c3

50

Move valve manually to the open


position. Allow for overrun by
winding actuator output closed by
1/2 to 1 turn.

PRESS THE

KEY.

5IFUXPCBSTXJMMGMBTI TUPSFE
BOEUIF
PQFOJOEJDBUPSMBNQXJMMJMMVNJOBUF 
indicating open limit position has been
TFU

PRESS THE

m KEY.

5IFPQFOTZNCPM(refer to Fig. 3.3.


page 4)TIPVMEOPXBQQFBS

NOTE: When in checking mode Set


Limit Open [LO]EPFTOPUBQQFBS

NOTE: When in checking mode Set


Limit Closed [LC]EPFTOPUBQQFBS

30

Return to
Positional Display
50

*GUIFQSPDFEVSFIBTCFFOGPMMPXFEBT
EFTDSJCFE UIFQPTJUJPOBMEJTQMBZXJMM
indicate that the actuator is in the open
QPTJUJPO

m
50
5PSRVF

m
P?

PC

Ir

c1

m
tC

m
LC

tP

With the correct settings made electric


PQFSBUJPODBOOPXCFDBSSJFEPVU
TBGFMZ

cr

4FMFDU3FNPUFDPOUSPMNPNFOUBSJMZ 
VTJOHUIFSFETFMFDUPSUPFYJUTFUUJOH
QSPDFEVSFBOEUIFOTFMFDUSFRVJSFE
DPOUSPM-PDBM 4UPQPS3FNPUF

c2

tO

LO

c3

50

63

31

Commissioning
Configuration Settings
The Configuration Settings can be
configured to suit site control and
JOEJDBUJPOSFRVJSFNFOUT*UJTJNQPSUBOU
that Basic Settings such as limits and
UPSRVFTXJUDITFUUJOHTBSFTFUCFGPSF
XPSLDPNNFODFTPODPNNJTTJPOJOH
the Configuration Settings (refer to
page 22)
5IFMBZPVUPGUIF$POGJHVSBUJPO
4FUUJOHTBDDFTTFEXJUIUIF4FUUJOH5PPM
BSFEFUBJMFEJO'JH5PTVDDFTTGVMMZ
DPNNJTTJPOUIF$POGJHVSBUJPO4FUUJOHT 
information about the site or process
DPOUSPMTZTUFNXJMMCFSFRVJSFE
5IFTVQQMJFEBDUVBUPS8JSJOH%JBHSBN
EFUBJMTDPOUSPMBOEJOEJDBUJPOEFWJDFT
GJUUFEUPUIFBDUVBUPSBMPOHXJUI
terminal connection detail and standard
SFNPUFDPOUSPMXJSJOHTZTUFNT

Power Off Setting


*2BMMPXTTFUUJOHTUPCFWJFXFEBOE
TFUXJUIPVUNBJOTQPXFS5PFOBCMF
UIJTGVODUJPO FOHBHFIBOEXIFFMESJWF
BOESPUBUFVOUJMUIFPVUQVUESJWFNPWFT
CZPOFUVSO(refer to page 3)5IF
4FUUJOH5PPMDBOOPXCFVTFE"T
MPOHBTB4FUUJOH5PPMLFZQSFTTUBLFT
QMBDFXJUIJOUIFTFDPOETUJNFPVU
QFSJPE 1PXFS0GG4FUUJOHXJMMSFNBJO
FOBCMFE*GOPJOGSBSFE4FUUJOH5PPM
DPNNVOJDBUJPOUBLFTQMBDFUIFEJTQMBZ
XJMMSFUVSOUPJOEJDBUJOHQPTJUJPO5IF
BDUVBUPSNVTUUIFOCFPQFSBUFECZ
IBOEXIFFMUPSFFOBCMF1PXFS0GG
4FUUJOH

Settings and operation must


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

Fig. 9

32
50 Positional Display

m
5PSRVF

m
P?

m
cr

k
k

IrDA
comms

PC

Ir

Torque Reference
Profile

tP

Contact Function

Value

r1

r1

r1

r2

r2

r2

r3

r3

r3

r4

r4

r4

Contact S1

Contact S2

Primary
Functions

Contact S3

Contact S4

&4%
&4%5IFSNPTUBU &4%0WFSJEF  &4%0WFSSJEF  .BJOUBJOFE 
&4%"DUJPO  $POUBDU5ZQF 
#ZQBTT
 *OUFSMPDLT  -PDBM4UPQ  -PDBM$POUSPM 

Control Mode
Configuration

A1

&YUSB*OEJDBUJPO
Contacts

Option Selection
Option Functions

Service Mode
Help Screens
Default Option


Contact Form

OE

A2
N"
CPT

OI

k


A3

3FNPUF

Control Source 

Od

A4
*OUFSSVQUFS
5JNFS

OJ

A5

A6

 4FUUJOH5PPM 
 -PDBM$POUSPM 

1PXFS-PTT
*OIJCJU

Or

OS

k



XJSF
$POUSPM

A7
$IPPTF
-&%$PMPVS

OH

&YUFSOBM*OUFSMPDLT $POEJUJPOBM  5PSRVF4XJUDI


$POUSPM

#ZQBTT
 1BSUJBM4USPLF 

A8




.JE5SBWFM
-&%

OU

A9

-BOHVBHF

At

UL

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

4PGUXBSF
7FSTJPO




Un

H1
d1

m
m
m

0QUJPO
7FSTJPO




UI

H2

d2

3FUVSOUP1PTJUJPOBM%JTQMBZ

0QUJPO
7FSTJPO




U2

H3


3FTFU




4FSWJDF
1BTTXPSE

Ur

H4

H5

H6

H7

H8

UP

64

H9

Fig. 9.1 Configuration Settings

9.1
CONFIGURATION SETTINGS
page
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
9.13
9.14
9.15
9.16
9.17
9.18
10.2
10.3

9.2

Accessing the Configuration Settings


Indication Contacts S1, S2, S3 and S4
Control Mode Configuration
Option Extra Indication Contacts S5S8
Option CPT (4-20mA Indication)
Option Folomatic (Analogue Position Control)
Remote Control Source
Bus System Option Pakscan
Bus System Option Modbus
Bus System Option Profibus DP
Bus System Option DeviceNet
Bus System Positioning Control Settings
Option Interrupter Timer
Setting Tool Local Control
Inhibit Operation After Power Loss
Indicator LEDs
Display Language
Default Options
Help Screens
IrDA Diagnostics and Configuration

33
34
36
39
40
41
44
45
48
51
54
57
59
61
61
62
62
64
71
76

)BWJOHFTUBCMJTIFEUIBUUIF#BTJD
4FUUJOHTIBWFCFFODPSSFDUMZTFU UIF
$POGJHVSBUJPO4FUUJOHTDBOOPXCF
configured to suit site control and
JOEJDBUJPOSFRVJSFNFOUT
*UJTQPTTJCMFUPNPWFUISPVHIUIF
WBSJPVT$POGJHVSBUJPO4FUUJOHTBTTIPXO
JO'JHVTJOHUIFk and m LFZT
5IFBDUVBUPSXJSJOHEJBHSBNXJMM
JOEJDBUFBOZPQUJPOTGJUUFE

Code

Function BTEJTQMBZFE

[CL]
[OP]
[Po]
[rr]
[dC]
[dO]
[d?]
[HA]
[bL]
[UA]
[tC]
[tO]
[tt]
[tl]
[St]
[LS]
[Lo]
[rE]
[CA]
[ES]

Closed Limit
Open Limit
Position % Open
Motor Running
Closing
Opening
Moving
Hand Operation
Moving-Blinker
Valve Alarm
Torque Trip Close (direction)
Torque Trip Open (direction)
Torque Trip  BOZQPTJUJPO

Torque Trip Mid  USBWFM

Motor Stalled
Stop Selected
Local Selected
Remote Selected
Control Alarm
ESD Active

*OPSEFSUPEJTQMBZUIF$POGJHVSBUJPO
4FUUJOHTJUJTOFDFTTBSZUPQSFTTUIFm
LFZVOUJM[Cr]BQQFBST
*GZPVIBWFDIPTFOUPFOUFS
Configuration Settings in the checking
NPEFUIFEJTQMBZXJMMCFBT'JH
*GZPVIBWFDIPTFOUPFOUFS
Configuration Settings in the setting
NPEFUIFEJTQMBZXJMMCFBT'JH
(refer to Section 7)

Basic Setup
Config Setup

Basic Setup
Config Setup

Fig. 9.2

Fig. 9.3

PRESS THE k KEY

r1
[Ol]
[Cl]
[lL]
[AA]
[Ht]
[LP]
[24]
[bA]
[rP]
[PA]
[PE]

33

Options Setting Tool Local Control


[Or]BOE1PXFS-PTT*OIJCJU[OS] are
TUBOEBSEGFBUVSFT UIFJSVTFCFJOH
PQUJPOBM

Indication Contacts
S1, S2, S3 and S4

*OEJDBUJPODPOUBDUT4<S> 4<S> 4


<S>BOE4<S>NBZFBDICFTFUUPUSJQ
GPSBOZPOFPGUIFGPMMPXJOHGVODUJPOT

Accessing the
Configuration Settings

Open Interlock Active


Close Interlock
Interlock Active
Actuator Alarm
Thermostat Tripped
Lost Phase *
24V Power Failure **
Battery Low
Relay Parity
Partial Stroke Active
Partial Stroke Error

* [LP]'VODUJPOOPUBWBJMBCMFGPSQIBTFT
 POMZGPSQIBTF'PSQIBTFMPTT
EFUFDUJPOPOQIBTFQMFBTFVTF
NPOJUPSSFMBZ
** [24]'VODUJPOOPUBWBJMBCMFJGUIF
QIBTFTVQQMZJTMPTU

34

Contact S1 - Function

Using the + or -LFZEJTQMBZUIFEFTJSFE


GVODUJPO

PRESS THE

KEY.

5IFEJTQMBZFEGVODUJPOXJMMGMBTI
JOEJDBUJOHUIBUJUIBTCFFOTFU

S1 Function
Close Limit

5IF4DPOUBDUGPSNDBOCFTFUOPSNBMMZ
open [no]PSOPSNBMMZDMPTFE[nc]
The procedures for setting up contacts
4 4BOE4BSFUIFTBNFBTUIPTF
TIPXOGPS4

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]

65

Contact S1 Configured to Trip


at Valve Closed Limit

PRESS THE

k KEY.

r1

Contact S1 - Value

5IJTTDSFFOXJMMPOMZEJTQMBZJGSFMBZ
function is set to [P0] Position Open 
When the S contact function is set to
[P0] UIFSFRVJSFEJOUFSNFEJBUFQPTJUJPO
WBMVFNVTUCFTFU

No other contact function requires


a value to be set.

r1

35

Contact S1
Contact Form

Use the + or -LFZTUPTFMFDUCFUXFFO


[nO] Normally Open and [nC] Normally
Closed 

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

5IFWBMVFDBOCFTFUGSPNPQFOUP
PQFOJOJODSFNFOUT
Using the + or -LFZ EJTQMBZUIF
SFRVJSFEWBMVF

PRESS THE

S1 Contact
Normally Open

KEY.

5IFEJTQMBZFEWBMVFXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

Contact S1 Configured as a
Normally Open Contact

NOTE: If function [PO] Position Open


S1 % Position
25%

Value Set to Indicate


25% Open

PRESS THE

9.3

is selected and it is configured as a


OPSNBMMZPQFODPOUBDUJUXJMMNBLFBU
UIFTFUWBMVFXJUIUIFBDUVBUPSNPWJOH
JOUIFPQFOEJSFDUJPO
5PBDDFTT4o4

PRESS THE

m KEY.

k KEY.

Control Mode
Configuration

The Control Mode Configuration affects


IPXUIFBDUVBUPSXJMMSFTQPOEVOEFS
DPOEJUJPOTPGFNFSHFODZTIVUEPXO 
MPDBMDPOUSPM SFNPUFDPOUSPMJOUFSMPDLT 
BOEXJSFSFNPUFDPOUSPM"MTP
JODMVEFEJTBOVOTFBUJOHUPSRVFTXJUDI
CZQBTTGVODUJPO6OMFTTTQFDJGJFEXJUI
PSEFS UIFDPOUSPMNPEFDPOGJHVSBUJPO
XJMMCFTFUBTTIPXOGPSEFGBVMU
DPOGJHVSBUJPOPOQBHF
*GJUJTOFDFTTBSZUPDIBOHFUIF
DPOGJHVSBUJPOGPMMPXUIFJOTUSVDUJPOTJO
UIJTTFDUJPO

A1

A2

ESD Action

"OBDUJWF&4%TJHOBMBQQMJFEUPUIF
BDUVBUPSXJMMPWFSSJEFBOZFYJTUJOHPS
BQQMJFEMPDBMPSSFNPUFDPOUSPMTJHOBM
&4%DBOCFDPOGJHVSFEUPPWFSSJEFUIF
NPUPSUIFSNPTUBU BDUJWFJOUFSMPDLTPS
MPDBMTUPQTFMFDUJPO3FGFSUP" "
BOE"
5IFEFGBVMUBDUJPOVOEFSBOBDUJWF&4%
TJHOBMJTUPTUBZQVU[SP] Stay Put 
Press the + or -LFZUPTFMFDUUIF
SFRVJSFE&4%BDUJPO

ESD Contact Type

5IFEFGBVMUTFUUJOHGPS&4%$POUBDU
5ZQFJT[nO] Normally Open 
'PSBDUVBUPSTTFUUP&4%[nO] Normally
Open UIF&4%4JHOBMNVTUCFBQQMJFE
UPBDUJWBUFUIF&4%DPNNBOE'PS&4%
[nC] Normally Closed the signal must
CFSFNPWFEUPBDUJWBUFUIFDPNNBOE
Press the + or -LFZUPDIPPTFUIF
DPOUBDUUZQF

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPO TUPSFE
XJMMGMBTI
JOEJDBUJOHUIBUJUIBTCFFOTFU

[OF] Off PO&4%

A3

ESD Override
Thermostat

36

5IFEFGBVMUTFUUJOHGPS&4%0WFSSJEF
Thermostat is [OF] No EVSJOH&4%
The thermostats remain in circuit and
FOBCMFEEVSJOH&4%
5IFNPUPSUIFSNPTUBUTDBOCFCZQBTTFE
EVSJOH&4%BTBGBDUPSZTFU IBSE
XJSFEPQUJPOPOMZ$POUBDU3PUPSLGPS
JOGPSNBUJPO

Danger: Actuator hazardous


area certification is invalidated
while the thermostats are
bypassed.
[A3]TIPVMECFTFUUPSFGMFDUUIFGBDUPSZ
TFUDPOGJHVSBUJPOPGUIFSNPTUBUCZQBTT

There are 10 configurable control


functions:

[CL] Close PO&4%

Code

Function BTEJTQMBZFE

[OP] Open PO&4%

[A1]

ESD Action

PRESS THE

[A2]
[A3]
[A4]
[A5]
[A6]
[A7]
[A8]
[A9]
[At]

ESD Contact Type


ESD Override Stat
ESD Override Interlocks
ESD Override Local Stop
Maintain Local Control
2-wire Remote Priority
Interlocks
Conditional Control
Torque Switch Bypass.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

[SP] Stay Put PO&4%

%VSJOHBO&4%FWFOU
ESD Contact Type
Normally Open

KEY.

[A3] = [OF] No UIFSNPTUBUTFOBCMFE


[A3] = [On] Yes UIFSNPTUBUTCZQBTTFE

Actuator Responds to a Normally


Open ESD Contact (Signal Applied)
ESD Override
Stat: No

ESD Action
Close

66

A4

ESD Override
Interlocks

5IFEFGBVMUTFUUJOHGPS&4%0WFSSJEF
Interlocks is [OF] No &4%BDUJPOXJMMOPU
PWFSSJEFBOBDUJWFJOUFSMPDLBQQMJFEUP
UIFBDUVBUPS
*GBOBQQMJFE&4%TJHOBMJTSFRVJSFEUP
PWFSSJEFBDUJWFJOUFSMPDLTDBVTJOHUIF
&4%BDUJPOBTTFUGPS" QSFTTUIF
+ or -LFZ5IFEJTQMBZXJMMDIBOHFUP
[On] Yes 

PRESS THE

KEY.

A5

A6

ESD Override
Local Stop

Maintain
Local Control

5IFEFGBVMUTFUUJOHGPS&4%0WFSSJEF
Local Stop is [OF] No &4%XJMMOPU
PWFSSJEFMPDBMTUPQXIFOTFMFDUFE

The default setting for Local Actuator


Pushbutton control is self-maintained
[On] Yes 

*GBOBQQMJFE&4%TJHOBMJTSFRVJSFEUP
PWFSSJEFMPDBMTUPQDBVTJOHUIF&4%
BDUJPOBTTFUGPS" QSFTTUIF+ or -LFZ
5IFEJTQMBZXJMMDIBOHFUP[On] Yes 

If non-maintained actuator pushbutton


DPOUSPMJTSFRVJSFE KPHHJOH JODIJOH 
QVTIUPSVO
QSFTTUIF+ or -LFZ5IF
EJTQMBZXJMMDIBOHFUP[OF] No 

PRESS THE

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

A7

2-wire Remote
Priority

37

5IFEFGBVMUTFUUJOHGPSXJSF3FNPUF
1SJPSJUZJT[SP] Stay Put *GBOPQFOBOE
closed remote control signal are applied
TJNVMUBOFPVTMZUIFBDUVBUPSXJMMTUBZ
QVU TUPQJGSVOOJOH
3FGFSUPBDUVBUPS
XJSJOHEJBHSBNPSQVCMJDBUJPO&&
Use the + or -LFZUPTFMFDUUIF
SFRVJSFEQSJPSJUZ
[OP] Open
[SP] Stay Put
[CL] Close

PRESS THE
ESD Override
Local Stop: No

Maintain Local
Control: Yes

ESD Override
Interlocks: No

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

2-Wire Remote
Priority: Stay

2-wire Control Stay Put Priority

A8

Interlocks

A8

A9

Partial Stroke

"DUVBUPSTBSFEFMJWFSFEXJUIUIF
JOUFSMPDLGBDJMJUZEJTBCMFE[OF] Disabled 
3FGFSUPUIFBDUVBUPSXJSJOHEJBHSBNPS
publication E120E for interlock control
DJSDVJUT

5IFBDUVBUPSDBOCFTFUUPDBSSZPVUB
partial stroke test using a signal applied
to the open interlock input to initiate
BQBSUJBMTUSPLFUFTU3FGFSUPXJSJOH
EJBHSBN

5PFOBCMFSFNPUFFYUFSOBMJOUFSMPDLT
press the + or -LFZ

5IFEFGBVMUGPSQBSUJBMTUSPLFJOUFSMPDLT
is [OF] Disabled 

5IFEJTQMBZXJMMDIBOHFUP[On]

To enable partial stroke testing press


the + or -LFZ

Enabled 
PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
Interlocks
Disabled

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.

8IFSFBIJHIMFWFMPGTBGFUZJOUFHSJUZ
JTSFRVJSFE $POEJUJPOBM$POUSPMDBO
CFDPOGJHVSFE*OUIJTNPEFUXP
EJTDSFFUTJHOBMTBSFSFRVJSFEGPSSFNPUF
PQFSBUJPO3FNPUFDPOUSPMXJMMCF
conditional on both a control signal
(open or close) and the appropriate
interlock signal being applied
TJNVMUBOFPVTMZ'BJMVSFPGFJUIFSPSB
TQVSJPVTTJHOBMXJMMOPUDBVTFPQFSBUJPO
Interlocks [A8] must be set [On]
Enabled *OUFSMPDLTJHOBMTBSFOPU
SFRVJSFEGPSMPDBMPQFSBUJPO

5IFEJTQMBZXJMMDIBOHFUP[PS] Partial
Stroke 

PRESS THE

Conditional Control

The default setting for conditional


control is [OF] Disabled 5PFOBCMF
conditional control press the + or LFZ5IFEJTQMBZXJMMDIBOHFUP[On]
Enabled 

PRESS THE
Interlocks
Partial Stroke

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

At

38

Torque Switch Bypass

5IFEFGBVMUTFUUJOHGPS5PSRVF4XJUDI
#ZQBTTJT[OF] Off UIFUPSRVFTXJUDIFT
BSFOPUCZQBTTFEEVSJOHUIFVOTFBUJOH
NPWFNFOU
5PCZQBTTUIFUPSRVFTXJUDIFTEVSJOH
UIFVOTFBUJOHNPWFNFOUQSFTTUIF+
or -LFZ
5IFEJTQMBZXJMMDIBOHFUP[On]

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
5IFUPSRVFTXJUDIFTXJMMCFCZQBTTFE
GSPNDMPTFEMJNJUUPPQFOXIFO
PQFOJOHBOEGSPNPQFOMJNJUUP
XIFODMPTJOH#ZQBTTJOHUIFUPSRVF
TXJUDIFTNBLFTUPSRVFJOFYDFTTPG
SBUFEBOEVQUPBDUVBUPSTUBMMBWBJMBCMF
GPSVOTFBUJOHBAATUJDLZWBMWF0VUTJEF
UIFTFQPTJUJPOTUIFUPSRVFTFUUJOHXJMM
SFWFSUUPUIFWBMVFTTFUGPS[tC] Close
Torque TFFQBHFBOE[tO] Open
Torque QBHF

To access partial stroke test settings

PRESS THE

m KEY.

3FGFSUP"QQFOEJY" QBHFGPS
JOTUSVDUJPOTPOQBSUJBMTUSPLFTFUUJOHT

Conditional
Control: Disabled

67

Torque Switch
Bypass: Off

9.4

Option Extra
Indication Contacts

&YUSBJOEJDBUJPODPOUBDUT4[r5] 4
[r6] 4[r7] and S8 [r8]BSFBWBJMBCMFBT
BOPQUJPO

OE

Display Extra Contact


Set-up Screens

39

5IFBDUJPOPGUVSOJOHPOUIF&YUSB
Contact Option makes an additional
TFSJFTPGTFUVQTDSFFOTBWBJMBCMF

Check actuator circuit diagram for


JODMVTJPO
8IFOUIF&YUSB$POUBDU0QUJPOJT
included the set-up procedure and
BWBJMBCMFDPOUBDUGVODUJPOTGPS4o4
BSFJEFOUJDBMUP4o4(refer to Section
9.2 page 34)
6OMFTTTQFDJGJFEXJUIPSEFSUIFEFGBVMU
TFUUJOHGPSUIFFYUSBJOEJDBUJPODPOUBDUT
XJMMCFBTGPMMPXT
S5 [r5] Close limit

Press the + or -LFZUPTFMFDUUIF&YUSB


Contact Option set-up screens [On]

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

S6 [r6] Open limit


S7 [r7] Torque trip mid
S8 [r8] Remote selected

NOTE:*GUIF&YUSB$POUBDU0QUJPOJT
OPUJODMVEFEJOUIFBDUVBUPSCVJME BOZ
TFUUJOHTNBEFGPS4o4XJMMIBWFOP
effect on the indication output of the
BDUVBUPS

9.5

Extra Contacts
Menu: Off

Extra Contacts
Menu: On

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)

40

Option CPT [OI]


4-20mA Indicator

Setting instructions for actuators


including a CPT providing 4-20mA
analogue position feedback.
5IF$15JTBOPQUJPOBMFYUSB*UNBZCF
JOUFSOBMMZPSFYUFSOBMMZQPXFSFE

NOTE: If the actuator has options


'PMPNBUJDBOE$15 SFEFGJOJOHUIF
$15 XJMMSFRVJSFUIF'PMPNBUJDUPCF
recommissioned (refer to Section 9.6
Folomatic [OI] page 41)

$IFDLXJSJOHEJBHSBNGPSJODMVTJPOBOE
DPOOFDUJPOEFUBJMT

Analog Feedback
CL=4mA OP=20mA

With [HI]%JTQMBZFE UIF$15PQFSBUFT

Close=4mA Open=20mA
If Close=20mA Open=4mA JTSFRVJSFE VTF
the + or -LFZUPDIBOHFUP[LO]

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUUIFPQUJPOIBTCFFOTFU

68

9.6

OI

Option Folomatic
Analogue Control

Setting instructions for


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

This instruction lists the Folomatic


GVODUJPOEJTQMBZTJOUIFJSTFRVFODFBOE
assumes that all Folomatic functions are
UPCFDIFDLFETFU

The Folomatic is an optional


control device. Check actuator
wiring diagram for inclusion.

The actuator should be selected in Local


PS4UPQXJUIUIFBOBMPHVFJOQVUTJHOBM
connected to terminals 26(+ve) and
27(ve) (refer to wiring diagram)

Folomatic Feedback

Before commissioning of the Folomatic


GVODUJPOTDBOCFHJO UIF'PMPNBUJD
Feedback must be set to suit the
BQQMJFETFUQPJOUTJHOBM

FI

Analogue
Signal Type

Using the + or -LFZTFMFDU[ l] Current


for current input signal or [ U] Voltage
GPSWPMUBHFJOQVUTJHOBM

Analog Signal
Type: Current

Analog Feedback
CL=4mA OP=20mA

Before setting the parameters for


Option Folomatic ensure Remote
Control Source [Od] has been
selected to [bo] in Section 9.7.

With [HI]EJTQMBZFE BN"TJHOBMXJMM


DPSSFTQPOEUPUIFWBMWFPQFOJOH
*GBIJHIJOQVUTJHOBMJTSFRVJSFEUP
DPSSFTQPOEUPWBMWFDMPTJOHVTFUIF
+ or -LFZUPDIBOHFUP[LO] CL=20mA 

'PMPNBUJDTFUVQTDSFFOTXJMMCF
BVUPNBUJDBMMZEJTQMBZFEXIFOUIF
PQUJPOJTGJUUFE3FGFSUPBDUVBUPSXJSJOH
EJBHSBN

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
If setting [OI] is modified after
DPNNJTTJPOJOHUIF'PMPNBUJD JUXJMM
CFOFDFTTBSZUPSFDPNNJTTJPOUIF
'PMPNBUJD

41

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
5IFTJHOBMUZQFTFMFDUFEXJMMEFUFSNJOF
XIBUJTEJTQMBZFEPOUIFJOQVUTJHOBM
range screen [Fr] Analog Signal 
Press the kLFZUPEJTQMBZ
[Fr] Analog Signal 

Press the mLFZUPBDDFTTUIF


'PMPNBUJDTFUVQEJTQMBZNFOVT

Fr

Input
Signal Range

FL

FH

Valve Position
LOW Set Point

Valve Position
HIGH Set Point

Using the + or -LFZTFMFDUGPSSFRVJSFE


TJHOBMXJUIJOUIFSBOHFPGoN"PS
WPMUT oN"PSWPMUTPSoN"PS
WPMUT JFoN"


APPLY MINIMUM
SET POINT SIGNAL
Using the + or -LFZTFMFDU

APPLY MAXIMUM
SET POINT SIGNAL
Using the + or -LFZTFMFDU

If [FI] is set to current N"SBOHFTXJMM


CFEJTQMBZFE*G[FI] is set to Voltage 
WPMUBHFSBOHFTXJMMCFEJTQMBZFE.

[ ] [ ] Closed 
[00] to [99]
] Open 
[

[ ] [ ] Closed 
[00] to [99]
] Open 
[

WBMWFDMPTFE
= percentage open
WBMWFPQFO

UPDPSSFTQPOEXJUIUIFLOW set point


TJHOBM

WBMWFDMPTFE
= percentage open
WBMWFPQFO

UPDPSSFTQPOEXJUIUIFHIGH set point


TJHOBM

Analog Signal
Range: 4-20mA

020mA Range Selected

Analog Signal
Range: 0-20V

0-20V Range Selected

PRESS THE

KEY.

KEY.

Deadband
Adjustment

42

If the actuator hunts or responds


VOOFDFTTBSJMZUPBGMVDUVBUJOHJOQVU
TJHOBMUIFEFBECBOENVTUCFJODSFBTFE
*GNPSFBDDVSBUFDPOUSPMJTSFRVJSFEUIF
EFBECBOENBZCFEFDSFBTFE
Use the + or -LFZUPTFMFDUUIF
EFBECBOEXJEUI3BOHFo
DPSSFTQPOETUPoPGTFUQPJOU
TJHOBM
/05&.BYJNVNEFBECBOEJT
PGWBMWFTUSPLF/PSNBMMZ NJOJNVN
EFBECBOETIPVMEOPUCFMFTTUIBO

High Set Point


Position: Open

Low Set Point


Position: Closed

PRESS THE

Fd

PRESS THE

Deadband
1.2%

KEY.

5IFEJTQMBZFEWBMVFXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

5IFEJTQMBZFEWBMVFXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

PRESS THE

Press the kLFZUPEJTQMBZ


[FH] High Set Point Position 

Press the kLFZUPEJTQMBZ


[Fd] Deadband 

5IFEJTQMBZFEWBMVFXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

KEY.

Press the kLFZUPEJTQMBZ


[Ft] Motion Inhibit Time 

TheEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
Press the kLFZUPEJTQMBZ
[FL] Low Set Point Position 

69

Ft

Motion Inhibit
Timer Adjustment

The motion inhibit timer introduces


BEFMBZJOUIFBDUVBUPSSFTQPOTFUP
BSBQJEMZGMVDUVBUJOHJOQVUTJHOBM 
QSFWFOUJOHVOOFDFTTBSZNPWFNFOU
0ODFUIFTZTUFNTUBCJMJTFTUIFBDUVBUPS
XJMMSFTQPOEUPTUFBEZDIBOHFTJOUIF
JOQVUTJHOBMBTOFDFTTBSZ

FA

FF

Action On Loss of
Set Point Signal

Use + or -LFZUPFOBCMF[On] or
disable [OF] action on loss of set point
TJHOBM
[On]oFailsafe BTEFUFSNJOFECZ[FF]
[OF]o Go to Low SP

Failsafe Action

'BJMTBGFBDUJPOXIFO[FA] Loss of Signal


set to [On] Failsafe POMZ
Use + or -LFZUPTFMFDU POMPTTPG
input signal:
[Lo]oGo to Low SP position
[SP]oStay Put

Use + or -LFZUPBEKVTUNPUJPOJOIJCJU
UJNFJOTFDPOETSBOHFo/PSNBMMZ
it is recommended that motion inhibit
time should not be set to less than 5
seconds (refer to note on page 61)

[Hl]o Go to High SP QPTJUJPO


Loss of Signal
Failsafe

FC

Manual/Auto
Selection

43

6TJOHBTXJUDIFEJOQVUZPVDBOTFMFDU
CFUXFFO'PMPNBUJD "VUP
PQFSBUJPOBOE
.BOVBM IBSEXJSFESFNPUF
PQFSBUJPO
5IJTDBOCFVTFEJOBQQMJDBUJPOTXIFSF
ZPVXBOUUIFPQUJPOUPPWFSSJEFUIF
'PMPNBUJDUPBMMPXGVMMNBOVBMDPOUSPMPG
UIFBDUVBUPSGSPNUIFDPOUSPMSPPN
"DUVBUPSTEJTQBUDIFEXJMMIBWFUIJT
feature disabled as the default in order
UPNJOJNJTFDPNNJTTJPOJOHUJNF*GZPV
XPVMEMJLFUIJTGFBUVSFFOBCMFE VTFUIF
+ or -LFZUPTFMFDU[On]&OBCMFE

Failsafe Action
Go to Low SP

PRESS THE
Motion Inhibit
Time: 05 seconds

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

NOTE:'BJMTBGFBDUJPOi0/wXJMMCF
PRESS THE

KEY.

5IFEJTQMBZFEWBMVFXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
Press the kLFZUPEJTQMBZ
[FA] Loss of Signal 

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

FGGFDUJWFPOMZGPSTZTUFNTVTJOHBO
PGGTFUPSMJWF[FSPTJHOBMSBOHF GPS
FYBNQMFoN"

Manual / Auto
Disabled

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

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
6TJOHUIFXJSJOHEJBHSBNTVQQMJFEXJUI
UIFBDUVBUPS GPMMPXUIFJOTUSVDUJPOT
POIPXUPDPOOFDUUIF.BOVBM"VUP
TFMFDUJPOTXJUDI

Press the kLFZUPEJTQMBZ


[FF] Failsafe Action 

Commissioning of the Folomatic is


OPXDPNQMFUF3FNPUFDPOUSPMNBZCF
TFMFDUFE

9.7

Remote Control Source

5IFBWBJMBCMFGPSNTPGSFNPUFDPOUSPM
BSFMJTUFECFMPX
4UBOEBSEIBSEXJSFEDPOUSPM
2 - Analogue control-Option Folomatic
/FUXPSLDPOUSPMJODMVEJOH
Option Pakscan
Option Modbus
Option Profibus
Option Foundation Fieldbus

0QUJPO%FWJDF/FU
The setting for Remote Control Source
XJMMEFQFOEPOUIFUZQFPGSFNPUF
DPOUSPMSFRVJSFEBOEUIFPQUJPO
TQFDJGJFEBOEGJUUFE$IFDLBDUVBUPS
DJSDVJUEJBHSBNGPSSFNPUFDPOUSPMGPSN

Od

44

Remote Control Source

The setting of Remote Control Source


XJMMCFEFUFSNJOFECZUIFPQUJPOUIBU
IBTCFFOGJUUFE JGBOZ

To change the remote source press the


+ or -LFZVOUJMUIFSFRVJSFETFUUJOHJT
EJTQMBZFE

[rE] Hard-Wired Only 1VTICVUUPOSFMBZ


contact control

PRESS THE

[oP] Network 1BLTDBO 1SPGJCVT 



.PECVT 'PVOEBUJPO'JFMECVTPS

%FWJDF/FUDPOUSPM

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

[bo] Folomatic : Analogue Proportional


control
Control Type
Hard-wired Only

[OF] Remote Disabled : Remote control


disabled

Standard Hardwired
Remote Control

70

9.8

Bus System
Option Pakscan

Setting instructions for actuators


including an optional Pakscan Field
$POUSPM6OJUoDIFDLXJSJOHEJBHSBNGPS
JODMVTJPO

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)

PA

Pb

Pakscan Node
Address

The actuator Pakscan Field Control Unit


NVTUCFBMMPDBUFEBVOJRVFMPPQOPEF
BEESFTT
The actuator must be in Loopback
and isolated from Pakscan loop traffic
GPSJUTBEESFTTUPCFTFUPSDIBOHFE
-PPQCBDLDBOCFBDIJFWFEJOUXPXBZT
 5VSO0''UIFNBTUFSTUBUJPO
 *TPMBUFUIFBDUVBUPSGSPNUIF

XJSFDPOUSPMMPPQCPUIJOPVU

The actuator Pakscan Field Control Unit


baud rate must be set to the loop baud
SBUF'PSB1BLTDBOXJSFDPOUSPMMPPQ
the selected baud rate must be common
to the master station and all the field
DPOUSPMVOJUTJODMVEFEJOUIFMPPQ
The actuator must be in Loopback
and isolated from Pakscan loop traffic
GPSJUTCBVESBUFUPCFTFUPSDIBOHFE
-PPQCBDLDBOCFBDIJFWFEJOUXPXBZT
 5VSO0''UIFNBTUFSTUBUJPO

Using the + or -LFZTEJTQMBZUIF


SFRVJSFEMPPQBEESFTT

 *TPMBUFUIFBDUVBUPSGSPNUIF

XJSFDPOUSPMMPPQCPUIJOPVU

"EESFTTUPCFTFUXJUIJOUIFSBOHF
 o')FYBEFDJNBM
(refer to
table on page 79)

45

Pakscan
Baud Rate

Baud Rate
2400 Baud

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
Press the kLFZUPEJTQMBZ
[PF] Aux I/P Mask 

Using the + or -LFZTEJTQMBZUIF


SFRVJSFECBVESBUF
[01] = 110 baud
[03] = 300 baud

Node Address
Hex 01 : Dec 001

PRESS THE

[06] = 600 baud


[12] = 1200 baud

KEY.

[24] = 2400 baud

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
Press the kLFZUPEJTQMBZ
[Pb] Baud Rate 

PF

46

Pakscan Remote
Auxiliary Input Mask

5IF*2BDUVBUPSIBTUIFGBDJMJUZUPBDDFQUBVYJMJBSZJOQVUT "69o"69
5IFTF
BSFVTFEXIFOTVQQMFNFOUBSZSFNPUFDPOUSPMPSEJHJUBMBVYJMJBSZJOQVUTBSFSFRVJSFE
in addition to the standard control and feedback features incorporated into the
1BLTDBODBSE*UJTBMTPQPTTJCMFUPIBWFBDPNCJOBUJPOPGCPUISFNPUFDPOUSPMBOE
WPMUGSFFJOQVUTUPQSPWJEF GPSFYBNQMF PQFOBOEDMPTFDPOUSPMBTXFMMBTBIJHI
BOEMPXUBOLMFWFMBMBSNJOEJDBUJPO TVQQMJFEWJBBOFYUFSOBMUSBOTEVDFS
5IFIFYBEFDJNBMOVNCFSEJTQMBZFEVOEFS1'DBOCFDPOTJEFSFEBTBAATPGUXBSF
NBTL*UJTUIJTNBTLUIBUUFMMTUIF1BLTDBODBSEXIBUUZQFPGJOQVUUPFYQFDU 
DPOUSPMPSJOQVUTJHOBM BOEXIBUGPSNUIFJOQVUXJMMCF OPSNBMMZPQFOPSOPSNBMMZ
closed (refer to page 79 for Binary, Hexadecimal and Decimal Conversion Table)
5PEFDJQIFSUIFNBTLUIFOVNCFSOFFETUPCFTQMJUJOUPUXPTFQBSBUFIFYBEFDJNBM
DIBSBDUFST FBDIPGXIJDIDBOCFTVCEJWJEFEJOUPCJOBSZCJUT5IFGJSTUCJUT
SFQSFTFOUUIFGVODUJPOBOEUIFTFDPOESFQSFTFOUUIFJOQVUTPVSDF LOPXOBT
JOWFSU
1JDUPSJBMMZUIJTDBOCFSFQSFTFOUFEBT

Bits

Left side hex character


Aux 4 to 1 (function)
4321

Right side hex character


AUX 4 to 1 (Invert)
4321

o

&4%

#JU "69


o

4UPQ .BJOUBJO

#JU "69


o

$MPTF

#JU "69


o

0QFO

1. Function bit set to 0


"OZGVODUJPOCJUTFUUPAAJOEJDBUFTUIBUUIFQBSUJDVMBSBVYJOQVUJTUPCFUSFBUFEBT
BEJHJUBMTJHOBMGPSGJFMETUBUVTSFQPSUJOH FHBMFWFMTXJUDIPSNPUPSSVOOJOHTUBUVT
*GUIFDPSSFTQPOEJOHJOWFSUCJUJTTFUUPBAA BOPQFODPOUBDUJTSFQPSUFEBTBMPHJD
BOEBDMPTFEDPOUBDUJTSFQPSUFEBTBMPHJDAA JFUIJTXJMMJOWFSUUIFJOQVU

*GUIFDPSSFTQPOEJOHJOWFSUCJUJTTFUUPBAA BOPQFODPOUBDUJTSFQPSUFEBTBMPHJD
BOEBDMPTFEDPOUBDUJTSFQPSUFEBTBMPHJDAA JFUIJTHJWFTBOPOJOWFSUJOH
JOQVU


2. Function bit set to 1


"OZGVODUJPOCJUTFUUPAAJOEJDBUFTUIBUUIFQBSUJDVMBSBVYJOQVUJTUPCFUSFBUFEBT
BEJHJUBMDPNNBOEUPPQFSBUFUIFBDUVBUPS
8IFOUIFDPSSFTQPOEJOHJOWFSUCJUJTTFUUPBAAUIJTSFQSFTFOUTBO/$DPOUBDU
BTCFJOHUIFDPNNBOETPVSDF JFBDMPTJOHDPOUBDUEFFOFSHJTFTUIFJOQVUBOEBO
PQFOJOHDPOUBDUFOFSHJTFTUIFJOQVU

When used for remote control of the actuator bits 4 to 1 of the function character
IBWFCFFOEFTJHOBUFEBTGPMMPXT
#JU "69


Rules

8IFOUIFDPSSFTQPOEJOHJOWFSUCJUJTTFUUPBAA UIJTSFQSFTFOUTBO/0DPOUBDU
BTCFJOHUIFDPNNBOETPVSDF JFBDMPTJOHDPOUBDUFOFSHJTFTUIFJOQVUBOEBO
PQFOJOHDPOUBDUEFFOFSHJTFTUIFJOQVU

3. ESD Control
8IFOVTJOH&4% BVYJOQVU
UIF&4%DPOUBDUNPEFTFUUJOH[A2] should be set to
UIFEFGBVMUWBMVFPG[nO]5IF[A1]o&4%EJSFDUJPOTFUUJOHTIPVMECFTFUUPFJUIFS
0QFOPS$MPTFUIFWBMWF(refer to page 36)

8IFOVTFEGPSEJHJUBMTJHOBMJOQVUTUIFZBSFTJNQMZEFTJHOBUFEBT"69UP"69


4. Stop (Maintain) Control


8IFOFOFSHJTFEUIJTXJMMNBLFUIF"VYJOQVU0QFO$MPTF&4%DPOUSPMQVTIUPSVO 
OPONBJOUBJOFE

8IFOEFFOFSHJTFE UIF"VYJOQVU0QFO$MPTF&4%DPOUSPMXJMMCFNBJOUBJOFE

71

PF

PF

Pakscan Remote
Auxiliary Input (continued)

Pakscan Remote
Auxiliary Input

47

Using the + or -LFZTEJTQMBZUIF


SFRVJSFENBTLTFUUJOH

5. Remote I/P Setting


Ensure that the correct [Od] Control Type TFUUJOHJTTFMFDUFE SFGFSUPQBHF

For Pakscan this is [oP] Network 
5IFGBDUPSZEFGBVMUGPS[PF] Aux I/P Mask is [OF] 0000 1111 

Examples

Aux I/P Mask


Bits: 0000 1111

5IFGVMMSBOHFPGSFNPUFDPOUSPMTJTOFFEFE0QFOBOE$MPTFBSF/0BOE&4%
BOE4UPQNBJOUBJOJT/$

Auxiliary Input Mask [OF]

Aux I/P

4321

Function

1111

=F

Invert

0011

=3

PRESS THE

0QFOBOEDMPTFDPOUSPMJTSFRVJSFEBMPOHXJUIJOWFSUFEEJHJUBMTJHOBMJOQVUT
/PUFUIBUXJUIUIJTTFUUJOHUIFPQFOBOEDMPTFDPNNBOETXJMMCFNBJOUBJOFE

Aux I/P

4321

Function

0011

=3

Invert

0011

=3

For Pakscan module positioning settings


[OF] SFGFSUPQBHF
If Pakscan positioning control is
SFRVJSFE PRESS THE m KEY.

i.e. set [PF] to [33]

%JTQMBZ[FL] Low Set Point Position


(refer to page 57)

0OMZBO&4%JOQVUJTOFFEFE5IFSFRVJSFNFOUJTGPSQVTIUPSVODPOUSPMXJUIB
/0DPOUBDUJOQVU
Aux I/P

4321

Function

1100

=C

Invert

1000

=8

9.9

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

i.e. set [PF] to [F3]

i.e. set [PF] to [C8]

Bus System
Option Modbus [OP]

Setting instructions for actuators


including an optional Modbus RTU
NPEVMFoDIFDLXJSJOHEJBHSBNGPS
JODMVTJPO

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.

PA

Pb

Modbus Node
Address

The Modbus module must be allocated


BVOJRVFBEESFTT
To set the address the Modbus module
NVTUCFJTPMBUFEGSPNUIFIPTUCZ
EJTDPOOFDUJOHUIF34IJHIXBZPS
UVSOJOHPGGUIFIPTUEFWJDF
Using the + or -LFZTEJTQMBZUIF
SFRVJSFEBEESFTT
"EESFTTUPCFTFUXJUIJOUIFSBOHF 
UP')FYBEFDJNBM
*GBOBEESFTT
WBMVFPVUTJEFUIJTSBOHFJTFOUFSFE UIF
BEESFTTTFUXJMMSFWFSUUP GPS
PS
' GPSWBMVFBCPWF'


48

Modbus Baudrate

The Modbus module must be set to the


34IJHIXBZCBVESBUF5PTFUUIF
baudrate the Modbus module must be
JTPMBUFEGSPNUIFIPTUCZEJTDPOOFDUJOH
UIF34IJHIXBZPSUVSOJOHPGGUIF
IPTUEFWJDF
Using the + or -LFZTEJTQMBZUIF
SFRVJSFECBVESBUF
[01] = 110
[03] = 300
[12] = 1200
[48] = 4800
[19]
[57] = 57600

Node Address
Hex 01 : Dec 001

PRESS THE

[06] = 600
[24] = 2400
[96]
[38] = 38400
[11] = 115200

Baud Rate
2400 Baud

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
Press the kLFZUPEJTQMBZ
[Pb] Baud Rate 

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
Press the kLFZUPEJTQMBZ
[PF] Aux I/P Mask 

72

PF

49

Modbus Remote
Auxiliary Input

5IF*2BDUVBUPSIBTUIFGBDJMJUZUPBDDFQUBVYJMJBSZJOQVUT "69o"69
5IFTF
BSFVTFEXIFOTVQQMFNFOUBSZSFNPUFDPOUSPMPSEJHJUBMBVYJMJBSZJOQVUTBSFSFRVJSFE
in addition to the standard control and feedback features incorporated into the
.PECVTNPEVMF*UJTBMTPQPTTJCMFUPIBWFBDPNCJOBUJPOPGCPUISFNPUFDPOUSPM
BOEWPMUGSFFJOQVUTUPQSPWJEF GPSFYBNQMF PQFOBOEDMPTFDPOUSPMBTXFMMBTB
IJHIBOEMPXUBOLMFWFMBMBSNJOEJDBUJPO TVQQMJFEWJBBOFYUFSOBMUSBOTEVDFS
5IFIFYBEFDJNBMOVNCFSEJTQMBZFEVOEFS1'DBOCFDPOTJEFSFEBTBAATPGUXBSF
NBTL*UJTUIJTNBTLUIBUUFMMTUIF.PECVTNPEVMFXIBUUZQFPGJOQVUUPFYQFDU 
DPOUSPMPSJOQVUTJHOBM BOEXIBUGPSNUIFJOQVUXJMMCF OPSNBMMZPQFOPSOPSNBMMZ
closed (refer to page 79 for Binary, Hexadecimal and Decimal Conversion Table)
5PEFDJQIFSUIFNBTLUIFOVNCFSOFFETUPCFTQMJUJOUPUXPTFQBSBUFIFYBEFDJNBM
DIBSBDUFST FBDIPGXIJDIDBOCFTVCEJWJEFEJOUPCJOBSZCJUT5IFGJSTUCJUT
SFQSFTFOUUIFGVODUJPOBOEUIFTFDPOESFQSFTFOUUIFJOQVUTPVSDF LOPXOBT
JOWFSU
1JDUPSJBMMZUIJTDBOCFSFQSFTFOUFEBT

Bits

Left side hex character


Aux 4 to 1 (function)
4321

Right side hex character


AUX 4 to 1 (Invert)
4321

o

&4%

#JU "69


o

4UPQ .BJOUBJO

#JU "69


o

$MPTF

#JU "69


o

0QFO

1. Function bit set to 0


"OZGVODUJPOCJUTFUUPAAJOEJDBUFTUIBUUIFQBSUJDVMBSBVYJOQVUJTUPCFUSFBUFEBT
BEJHJUBMTJHOBMGPSGJFMETUBUVTSFQPSUJOH FHBMFWFMTXJUDIPSNPUPSSVOOJOHTUBUVT
*GUIFDPSSFTQPOEJOHJOWFSUCJUJTTFUUPBAA BOPQFODPOUBDUJTSFQPSUFEBTBMPHJD
AABOEBDMPTFEDPOUBDUJTSFQPSUFEBTBMPHJDAA JFUIJTXJMMJOWFSUUIFJOQVU

*GUIFDPSSFTQPOEJOHJOWFSUCJUJTTFUUPBAA BOPQFODPOUBDUJTSFQPSUFEBTBMPHJD
BOEBDMPTFEDPOUBDUJTSFQPSUFEBTBMPHJDAA JFUIJTHJWFTBOPOJOWFSUJOH
JOQVU


2. Function bit set to 1


"OZGVODUJPOCJUTFUUPAAJOEJDBUFTUIBUUIFQBSUJDVMBSBVYJOQVUJTUPCFUSFBUFEBT
BEJHJUBMDPNNBOEUPPQFSBUFUIFBDUVBUPS
8IFOUIFDPSSFTQPOEJOHJOWFSUCJUJTTFUUPBAAUIJTSFQSFTFOUTBO/$DPOUBDU
BTCFJOHUIFDPNNBOETPVSDF JFBDMPTJOHDPOUBDUEFFOFSHJTFTUIFJOQVUBOEBO
PQFOJOHDPOUBDUFOFSHJTFTUIFJOQVU

When used for remote control of the actuator bits 4 to 1 of the function character
IBWFCFFOEFTJHOBUFEBTGPMMPXT
#JU "69


Rules

8IFOUIFDPSSFTQPOEJOHJOWFSUCJUJTTFUUPBAA UIJTSFQSFTFOUTBO/0DPOUBDU
BTCFJOHUIFDPNNBOETPVSDF JFBDMPTJOHDPOUBDUFOFSHJTFTUIFJOQVUBOEBO
PQFOJOHDPOUBDUEFFOFSHJTFTUIFJOQVU

3. ESD Control
8IFOVTJOH&4% BVYJOQVU
UIF&4%DPOUBDUNPEFTFUUJOH[A2] should be set to
UIFEFGBVMUWBMVFPG[nO]5IF[A1]o&4%EJSFDUJPOTFUUJOHTIPVMECFTFUUPFJUIFS
0QFOPS$MPTFUIFWBMWF(refer to page 36)

8IFOVTFEGPSEJHJUBMTJHOBMJOQVUTUIFZBSFTJNQMZEFTJHOBUFEBT"69UP"69

4. Stop (Maintain) Control


8IFOFOFSHJTFEUIJTXJMMNBLFUIF"VYJOQVU0QFO$MPTFDPOUSPMQVTIUPSVO
8IFOEFFOFSHJTFE UIF"VYJOQVU0QFO$MPTFDPOUSPMXJMMCFNBJOUBJOFE&4%JT
BMXBZTQVTIUPSVO OPONBJOUBJOFE


PF

PP

Modbus Remote
Auxiliary Input (continued)

5. Remote I/P Setting


Ensure that the correct [Od] Control Type setting is selected (refer to page 44)

Using the + or -LFZTEJTQMBZUIF


SFRVJSFENBTLTFUUJOH

For Modbus this is [OP] Network 

Examples

Aux I/P Mask


Bits: 0000 1111

5IFGVMMSBOHFPGSFNPUFDPOUSPMTJTOFFEFE0QFOBOE$MPTFBSF/0BOE&4%
BOE4UPQNBJOUBJOJT/$
=F
= 3 i.e. set [PF] to [F3]

=3
= 3 i.e. set [PF] to [33]

PRESS THE

[En] Even QBSJUZCJU

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

Modbus Parity
None

Press the kLFZUPEJTQMBZ


[PP] Modbus Parity 

No Parity Bit

PRESS THE

0OMZBO&4%JOQVUJTOFFEFE5IFSFRVJSFNFOUJTGPSQVTIUPSVODPOUSPMXJUIB
/0DPOUBDUJOQVU
Aux I/P 4 3 2 1
Function 1 1 0 0
Invert
1000

[no] None  OP
QBSJUZCJU
[Od] Odd QBSJUZCJU

0QFOBOEDMPTFDPOUSPMJTSFRVJSFEBMPOHXJUIJOWFSUFEEJHJUBMTJHOBMJOQVUT
/PUFUIBUXJUIUIJTTFUUJOHUIFPQFOBOEDMPTFDPNNBOETXJMMCFNBJOUBJOFE

Aux I/P 4 3 2 1
Function 0 0 1 1
Invert
0011

8IFSF.PECVTQBSJUZCJUEFUFDUJPOJT
VTFEUIFNPEVMFNVTUCFTFUXJUIUIF
QBSJUZCJUTFUUJOHPGUIFIPTU
Using the + or -LFZTEJTQMBZUIF
SFRVJSFEQBSJUZCJU

5IFGBDUPSZEFGBVMUGPS[PF] Aux I/P Mask is [OF] 0000 1111 

Aux I/P 4 3 2 1
Function 1 1 1 1
Invert
0011

50

Modbus Parity

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

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

=C
= 8 i.e. set [PF] to [C8]

If Modbus positioning control and


action on loss of communication are
SFRVJSFE PRESS THE m KEY.
%JTQMBZ[FL] Low Set Point Position
(refer to page 57)

73

9.10

PA

Bus System
Option Profibus DP [OP]

Setting instructions for actuators


JODMVEJOHBOPQUJPOBM1SPGJCVT%1
NPEVMFoDIFDLXJSJOHEJBHSBNGPS
JODMVTJPO

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

51

Profibus Node
Address

5IF1SPGJCVT%1NPEVMFNVTUCF
BMMPDBUFEBVOJRVFBEESFTT
To set the address the Profibus module
NVTUCFJTPMBUFEGSPNUIFIPTUCZ
EJTDPOOFDUJOHUIF34IJHIXBZPS
UVSOJOHPGGUIFIPTUEFWJDF

Node Address
Hex 01 : Dec 001

PRESS THE

Using the + or -LFZTEJTQMBZUIF


SFRVJSFEBEESFTT
"EESFTTUPCFTFUXJUIJOUIFSBOHF
UP&)FYBEFDJNBM
(refer to
page 79 for conversion)*GBOBEESFTT
WBMVFPVUTJEFUIJTSBOHFJTFOUFSFE UIF
BEESFTTTFUXJMMSFWFSUUP GPS
PS
& GPSWBMVFBCPWF&


KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
Press the kUPEJTQMBZ
[Pb] Baud Rate 
[Pb] has no relevance for the
Rotork Profibus DP Mk.2 card.
5IFSFGPSF JGUIF3PUPSL1SPGJCVT%1.L
DBSEJTGJUUFE QSFTTUIFkUPEJTQMBZ
[PF] Aux I/P Mask 

The actuator power must be


cycled for the changes to take effect.

PF

52

Profibus Remote
Auxiliary Input

5IF*2BDUVBUPSIBTUIFGBDJMJUZUPBDDFQUBVYJMJBSZJOQVUT "69o"69
5IFTF
BSFVTFEXIFOTVQQMFNFOUBSZSFNPUFDPOUSPMPSEJHJUBMBVYJMJBSZJOQVUTBSFSFRVJSFE
in addition to the standard control and feedback features incorporated into the
1SPGJCVTNPEVMF*UJTBMTPQPTTJCMFUPIBWFBDPNCJOBUJPOPGCPUISFNPUFDPOUSPM
BOEWPMUGSFFJOQVUTUPQSPWJEF GPSFYBNQMF PQFOBOEDMPTFDPOUSPMBTXFMMBTB
IJHIBOEMPXUBOLMFWFMBMBSNJOEJDBUJPO TVQQMJFEWJBBOFYUFSOBMUSBOTEVDFS
5IFIFYBEFDJNBMOVNCFSEJTQMBZFEVOEFS1'DBOCFDPOTJEFSFEBTBAATPGUXBSF
NBTL*UJTUIJTNBTLUIBUUFMMTUIF1SPGJCVTNPEVMFXIBUUZQFPGJOQVUUPFYQFDU 
DPOUSPMPSJOQVUTJHOBM BOEXIBUGPSNUIFJOQVUXJMMCF OPSNBMMZPQFOPSOPSNBMMZ
closed (refer to page 79 for Binary, Hexadecimal and Decimal Conversion Table)
5PEFDJQIFSUIFNBTLUIFOVNCFSOFFETUPCFTQMJUJOUPUXPTFQBSBUFIFYBEFDJNBM
DIBSBDUFST FBDIPGXIJDIDBOCFTVCEJWJEFEJOUPCJOBSZCJUT5IFGJSTUCJUT
SFQSFTFOUUIFGVODUJPOBOEUIFTFDPOESFQSFTFOUUIFJOQVUTPVSDF LOPXOBT
JOWFSU
1JDUPSJBMMZUIJTDBOCFSFQSFTFOUFEBT

Bits

Left side hex character


Aux 4 to 1 (function)
4321

Right side hex character


AUX 4 to 1 (Invert)
4321

o

&4%

#JU "69


o

4UPQ .BJOUBJO

#JU "69


o

$MPTF

#JU "69


o

0QFO

1. Function bit set to 0


"OZGVODUJPOCJUTFUUPAAJOEJDBUFTUIBUUIFQBSUJDVMBSBVYJOQVUJTUPCFUSFBUFEBT
BEJHJUBMTJHOBMGPSGJFMETUBUVTSFQPSUJOH FHBMFWFMTXJUDIPSNPUPSSVOOJOHTUBUVT
*GUIFDPSSFTQPOEJOHJOWFSUCJUJTTFUUPBAA BOPQFODPOUBDUJTSFQPSUFEBTBMPHJD
AABOEBDMPTFEDPOUBDUJTSFQPSUFEBTBMPHJD JFUIJTXJMMJOWFSUUIFJOQVU

*GUIFDPSSFTQPOEJOHJOWFSUCJUJTTFUUPBAA BOPQFODPOUBDUJTSFQPSUFEBTBMPHJD
AABOEBDMPTFEDPOUBDUJTSFQPSUFEBTBMPHJDAA JFUIJTHJWFTBOPOJOWFSUJOH
JOQVU


2. Function bit set to 1


"OZGVODUJPOCJUTFUUPAAJOEJDBUFTUIBUUIFQBSUJDVMBSBVYJOQVUJTUPCFUSFBUFEBT
BEJHJUBMDPNNBOEUPPQFSBUFUIFBDUVBUPS
8IFOUIFDPSSFTQPOEJOHJOWFSUCJUJTTFUUPBAAUIJTSFQSFTFOUTBO/$DPOUBDU
BTCFJOHUIFDPNNBOETPVSDF JFBDMPTJOHDPOUBDUEFFOFSHJTFTUIFJOQVUBOEBO
PQFOJOHDPOUBDUFOFSHJTFTUIFJOQVU

When used for remote control of the actuator bits 4 to 1 of the function character
IBWFCFFOEFTJHOBUFEBTGPMMPXT
#JU "69


Rules

8IFOUIFDPSSFTQPOEJOHJOWFSUCJUJTTFUUPBAA UIJTSFQSFTFOUTBO/0DPOUBDU
BTCFJOHUIFDPNNBOETPVSDF JFBDMPTJOHDPOUBDUFOFSHJTFTUIFJOQVUBOEBO
PQFOJOHDPOUBDUEFFOFSHJTFTUIFJOQVU

3. ESD Control
8IFOVTJOH&4% BVYJOQVU
UIF&4%DPOUBDUNPEFTFUUJOH[A2] should be set to
UIFEFGBVMUWBMVFPG[nO]5IF[A1]o&4%EJSFDUJPOTFUUJOHTIPVMECFTFUUPFJUIFS
PQFOPSDMPTFUIFWBMWF(refer to page 36)

8IFOVTFEGPSEJHJUBMTJHOBMJOQVUTUIFZBSFTJNQMZEFTJHOBUFEBT"69UP"69

4. Stop/Maintain Control
8IFOFOFSHJTFEUIJTXJMMNBLFUIF"VYJOQVU0QFO$MPTFDPOUSPMQVTIUPSVO8IFO
EFFOFSHJTFE UIF"VYJOQVU0QFO$MPTFDPOUSPMXJMMCFNBJOUBJOFE&4%JTBMXBZT
QVTIUPSVO OPONBJOUBJOFE


74

PF

PF

Profibus Remote
Auxiliary Input (continued)

Profibus Remote
Auxiliary Input

53

Using the + or -LFZTEJTQMBZUIF


SFRVJSFENBTLTFUUJOH

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 
5IFGBDUPSZEFGBVMUGPS[PF] Aux I/P Mask is [OF] 0000 1111 

Examples

Aux I/P Mask


Bits: 0000 1111

5IFGVMMSBOHFPGSFNPUFDPOUSPMTJTOFFEFE0QFOBOE$MPTFBSF/0BOE&4%
BOE4UPQNBJOUBJOJT/$
Aux I/P 4 3 2 1
Function 1 1 1 1
Invert
0011

=F
= 3 i.e. set [PF] to [F3]

PRESS THE

0QFOBOEDMPTFDPOUSPMJTSFRVJSFEBMPOHXJUIJOWFSUFEEJHJUBMTJHOBMJOQVUT
/PUFUIBUXJUIUIJTTFUUJOHUIFPQFOBOEDMPTFDPNNBOETXJMMCFNBJOUBJOFE

Aux I/P 4 3 2 1
Function 0 0 1 1
Invert
0011

If Profibus positioning control and


action on loss of communication are
SFRVJSFE PRESS THE m KEY.

=3
= 3 i.e. set [PF] to [33]

%JTQMBZ[FL] Low Set Point Position


SFGFSUPQBHF


0OMZBO&4%JOQVUJTOFFEFE5IFSFRVJSFNFOUJTGPSQVTIUPSVODPOUSPMXJUIB
/0DPOUBDUJOQVU
Aux I/P 4 3 2 1
Function 1 1 0 0
Invert
1000

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

=C
= 8 i.e. set [PF] to [C8]

9.11 Option DeviceNet

PA

Pb

DeviceNet Node
Address

54

DeviceNet Baudrate

Setting instructions for actuators


JODMVEJOHBOPQUJPOBM%FWJDF/FU%'6
NPEVMFoDIFDLXJSJOHEJBHSBNGPS
JODMVTJPO

5IF%FWJDF/FUNPEVMFNVTUCF
BMMPDBUFEBVOJRVFBEESFTT

5IF%FWJDF/FUNPEVMFNVTUCFTFUUP
UIF%FWJDF/FUIJHIXBZCBVESBUF

Using the + or -LFZTEJTQMBZUIF


SFRVJSFEBEESFTT

Using the + or -LFZTEJTQMBZUIF


SFRVJSFECBVESBUF

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)

"EESFTTUPCFTFUXJUIJOUIFSBOHF 
UP')FYBEFDJNBM
4FFQBHFGPS
DPOWFSTJPO*GBOBEESFTTWBMVFPVUTJEF
UIJTSBOHFJTFOUFSFE UIFBEESFTTTFU
XJMMSFWFSUUP GPS
PS' GPSWBMVF
BCPWF'


[01] = 125 k baud


[03] = 250 k baud
[06] = 500 k baud

The actuator power must be


cycled for the changes to take effect.

Node Address
Hex 01 : Dec 001

PRESS THE

Baud Rate
500k baud

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
Press the kLFZUPEJTQMBZ
[Pb] Baud Rate 

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
Press the kLFZUPEJTQMBZ
[PF] Aux I/P Mask 

75

PF

55

DeviceNet Remote
Auxiliary Input

5IF*2BDUVBUPSIBTUIFGBDJMJUZUPBDDFQUBVYJMJBSZJOQVUT "69o"69
5IFTF
BSFVTFEXIFOTVQQMFNFOUBSZSFNPUFDPOUSPMPSWPMUGSFFEJHJUBMBVYJMJBSZJOQVUTBSF
SFRVJSFEJOBEEJUJPOUPUIFTUBOEBSEDPOUSPMBOEGFFECBDLGFBUVSFTJODPSQPSBUFE
JOUPUIF%FWJDF/FUNPEVMF*UJTBMTPQPTTJCMFUPIBWFBDPNCJOBUJPOPGCPUISFNPUF
DPOUSPMBOEWPMUGSFFJOQVUTUPQSPWJEF GPSFYBNQMF PQFOBOEDMPTFDPOUSPMBTXFMM
BTBIJHIBOEMPXUBOLMFWFMBMBSNJOEJDBUJPO TVQQMJFEWJBBOFYUFSOBMUSBOTEVDFS
5IFIFYBEFDJNBMOVNCFSEJTQMBZFEVOEFS1'DBOCFDPOTJEFSFEBTBAATPGUXBSF
NBTL*UJTUIJTNBTLUIBUUFMMTUIF%FWJDF/FUNPEVMFXIBUUZQFPGJOQVUUPFYQFDU 
DPOUSPMPSJOQVUTJHOBM BOEXIBUGPSNUIFJOQVUXJMMCF OPSNBMMZPQFOPSOPSNBMMZ
DMPTFE
5PEFDJQIFSUIFNBTLUIFOVNCFSOFFETUPCFTQMJUJOUPUXPTFQBSBUFIFYBEFDJNBM
DIBSBDUFST FBDIPGXIJDIDBOCFTVCEJWJEFEJOUPCJOBSZCJUT5IFGJSTUCJUT
SFQSFTFOUUIFGVODUJPOBOEUIFTFDPOESFQSFTFOUUIFJOQVUTPVSDF LOPXOBT
JOWFSU
1JDUPSJBMMZUIJTDBOCFSFQSFTFOUFEBT

Bits

Left side hex character


Aux 4 to 1 (function)
4321

o

&4%

#JU "69


o

4UPQ .BJOUBJO

#JU "69


o

$MPTF

#JU "69


o

0QFO

"OZGVODUJPOCJUTFUUPAAJOEJDBUFTUIBUUIFQBSUJDVMBSBVYJOQVUJTUPCFUSFBUFEBT
BEJHJUBMTJHOBMGPSGJFMETUBUVTSFQPSUJOH FHBMFWFMTXJUDIPSNPUPSSVOOJOHTUBUVT
*GUIFDPSSFTQPOEJOHJOWFSUCJUJTTFUUPB BOPQFODPOUBDUJTSFQPSUFEBTBMPHJD
AABOEBDMPTFDPOUBDUJTSFQPSUFEBTBMPHJDAA JFUIJTXJMMJOWFSUUIFJOQVU

*GUIFDPSSFTQPOEJOHJOWFSUCJUJTTFUUPBAA BOPQFODPOUBDUJTSFQPSUFEBTBMPHJD
BOEBDMPTFDPOUBDUJTSFQPSUFEBTBMPHJDAA JFUIJTHJWFTBOPOJOWFSUJOH
JOQVU


2. Function bit set to 1


"OZGVODUJPOCJUTFUUPAAJOEJDBUFTUIBUUIFQBSUJDVMBSBVYJOQVUJTUPCFUSFBUFEBT
BEJHJUBMDPNNBOEUPPQFSBUFUIFBDUVBUPS

8IFOUIFDPSSFTQPOEJOHJOWFSUCJUJTTFUUPBAA UIJTSFQSFTFOUTBO/0DPOUBDU
BTCFJOHUIFDPNNBOETPVSDF JFBDMPTJOHDPOUBDUFOFSHJTFTUIFJOQVUBOEBO
PQFOJOHDPOUBDUEFFOFSHJTFTUIFJOQVU

3. ESD Control
8IFOVTJOH&4% BVYJOQVU
UIF&4%DPOUBDUNPEFTFUUJOH[A2] should be set to
UIFEFGBVMUWBMVFPG[nO]5IF[A1]o&4%EJSFDUJPOTFUUJOHTIPVMECFTFUUPFJUIFS
PQFOPSDMPTFUIFWBMWF(refer to page 36)

8IFOVTFEGPSEJHJUBMTJHOBMJOQVUTUIFZBSFTJNQMZEFTJHOBUFEBT"69UP"69

PF

1. Function bit set to 0

8IFOUIFDPSSFTQPOEJOHJOWFSUCJUJTTFUUPBUIJTSFQSFTFOUTBO/$DPOUBDU
BTCFJOHUIFDPNNBOETPVSDF JFBDMPTJOHDPOUBDUEFFOFSHJTFTUIFJOQVUBOEBO
PQFOJOHDPOUBDUFOFSHJTFTUIFJOQVU

Right side hex character


AUX 4 to 1 (Invert)
4321

When used for remote control of the actuator bits 4 to 1 of the function character
IBWFCFFOEFTJHOBUFEBTGPMMPXT
#JU "69


Rules

4. Stop (Maintain) Control


8IFOFOFSHJTFEUIJTXJMMNBLFUIF"VYJOQVU0QFO$MPTFDPOUSPMQVTIUPSVO
8IFOEFFOFSHJTFE UIF"VYJOQVU0QFO$MPTFDPOUSPMXJMMCFNBJOUBJOFE&4%JT
BMXBZTQVTIUPSVO OPONBJOUBJOFE


56

DeviceNet Remote
Auxiliary Input (continued)

5. Remote I/P Setting


Ensure that the correct [Od] Control Type setting is selected (refer to page 44)

Using the + or -LFZTEJTQMBZUIF


SFRVJSFENBTLTFUUJOH

'PS%FWJDF/FUUIJTJT[OP] Network 
5IFGBDUPSZEFGBVMUGPS [PF] Aux I/P Mask is [OF] 0000 1111 

Examples

Aux I/P Mask


Bits: 0000 1111

5IFGVMMSBOHFPGSFNPUFDPOUSPMTJTOFFEFE0QFOBOE$MPTFBSF/0BOE&4%
BOE4UPQNBJOUBJOJT/$
Aux I/P 4 3 2 1
Function 1 1 1 1
Invert
0011

=F
= 3 i.e. set [PF] to [F3]

0QFOBOEDMPTFDPOUSPMJTSFRVJSFEBMPOHXJUIJOWFSUFEEJHJUBMTJHOBMJOQVUT
/PUFUIBUXJUIUIJTTFUUJOHUIFPQFOBOEDMPTFDPNNBOETXJMMCFNBJOUBJOFE

Aux I/P 4 3 2 1
Function 0 0 1 1
Invert
0011

PRESS THE

'PS%FWJDF/FUNPEVMFQPTJUJPOJOH
settings and action on loss of signal
setting [OF] (refer to page 57)

=3
= 3 i.e. set [PF] to [33]

0OMZBO&4%JOQVUJTOFFEFE5IFSFRVJSFNFOUJTGPSQVTIUPSVODPOUSPMXJUIB
/0DPOUBDUJOQVU
Aux I/P 4 3 2 1
Function 1 1 0 0
Invert
1000

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

=C
= 8 i.e. set [PF] to [C8]

76

9.12

Bus System Positioning


Control Settings

*GUIFTZTUFNDPOUSPMTUSBUFHZGPS
1BLTDBO .PECVT %FWJDF/FUPS
1SPGJCVTSFRVJSFTJOUFSNFEJBUFWBMWF
USBWFMQPTJUJPOJOHUPB%7 %FTJSFE
7BMVFWBMVFDPSSFTQPOEJOHUPSFRVJSFE
QPTJUJPO
UIFDPOUSPMQBSBNFUFSTJOUIJT
TFDUJPOOFFEUPCFTFUAA"DUJPOPO-PTT
PG4JHOBMQBSBNFUFSTBQQMZPOMZUP
.PECVTBOE1SPGJCVTTZTUFNT
Limited Range Positioning is a selectable
PQUJPOXIFSFCZQPTJUJPOJOHMJNJUT 
BOE DBOCFBUEJGGFSFOUQPTJUJPOT
to those used for digital Closed and
0QFOMJNJUDPNNBOET-JNJUFESBOHF
positioning can be set using the [FL]
Low Set Point Position and [FH] High Set
Point Position TDSFFOT
*UTIPVMECFOPUFEUIBUUIFBDUVBUPSXJMM
respond to a digital Open or Close host
DPNNBOECZNPWJOHUIFWBMWFUPUIF
TFUMJNJUTJSSFTQFDUJWFPGTFUUJOHTNBEF
GPSQPTJUJPOJOHDPOUSPM
4FUUJOHTGPS%FBECBOEBOE.PUJPO
*OIJCJU5JNFBGGFDUBDDVSBDZBOE
SFTQPOTFUJNF
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

Ft

Bus System
Motion Inhibit Time (MIT)

.*5TFUTUIFNJOJNVNUJNFCFUXFFO
TVDDFTTJWFQPTJUJPODPNNBOETCFJOH
BDUJPOFE*UJTVTFEJOTJUVBUJPOTUP
reduce the number of starts per hour
and to smooth out fluctuations if
DPOUJOVPVTQPTJUJPOJOHJTJNQMFNFOUFE
4FUUJOHUIFMPOHFTUQPTTJCMFUJNFXIJMF
NBJOUBJOJOHBDDFQUBCMFDPOUSPMXJMM
NBYJNJTFUIFMJGFPGUIFNPUPSJTFE
WBMWF

FL

FH

Bus System Valve


Position at 0% DV

Bus System Valve


Position at 100% DV

[FL] Low Set Point Position is the position


UPXIJDIUIFBDUVBUPSXJMMNPWFJGB
DPNNBOEJTTFOU

[FH] High Set Point Position is the


QPTJUJPOUPXIJDIUIFBDUVBUPSXJMM
NPWFJGBDPNNBOEJTTFOU

Note that the position set for [FL]XJMM


CFSFQPSUFEUPUIFIPTUBT5IF
BDUVBUPSEJTQMBZXJMMSFQPSUPQFOJO
UIFSBOHFTFUCZUIFMJNJUT

Note that the position set for [FH]XJMM


CFSFQPSUFEUPUIFIPTUBT5IF
BDUVBUPSEJTQMBZXJMMSFQPSUPQFOJO
UIFSBOHFTFUCZUIFMJNJUT

5IFEFGBVMUTFUUJOHJTGPSUPCFUIF
$MPTFMJNJU

5IFEFGBVMUTFUUJOHJTGPSUPCF
UIF0QFOMJNJU

Use the + or -LFZUPTFMFDUUIFEFTJSFE


WBMWFQPTJUJPOGPSBDPNNBOE

Use the + or -LFZUPTFMFDUUIFEFTJSFE


WBMWFQPTJUJPOGPSBDPNNBOE

Low Set Point


Position: Closed

High Set Point


Position: Open

0% DV = Valve Closed

100% DV = Valve Open

PRESS THE

KEY.

PRESS THE

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

Press the kLFZUPEJTQMBZ


[FH] High Set Point Position 

Press the kLFZUPEJTQMBZ


[Fd] Deadband 

FA

Modbus, Profibus &


DeviceNet
Action on Loss of Signal

.PECVT 1SPGJCVT%FWJDF/FUNPEVMFT
can be set to respond on loss of host
DPNNVOJDBUJPOCZQPTJUJPOJOHUIF
WBMWF.PECVTDIFDLTGPSBMPTTPG
HFOFSBMIJHIXBZDPNNVOJDBUJPOT
XIFSFBT1SPGJCVT%FWJDF/FUDIFDL
for a loss of communications addressed
TQFDJGJDBMMZUPUIFNTFMWFT

FF

Modbus, Profibus
& DeviceNet
Failsafe Action

.PECVT 1SPGJCVT%FWJDF/FUGBJMTBGF
BDUJPOXIFO[FA]JTFOBCMFE
Use the + or -LFZUPEJTQMBZUIF
SFRVJSFETFUUJOH
[Lo] Go to Low SP QPTJUJPO
[SP] Stay put
[HI] Go to High SP QPTJUJPO

The default setting is off [OF] and the


EFGBVMUUJNFPVUJTTFD

[On] Failsafe BTEFUFSNJOFECZTFUUJOH[FF]

Failsafe Action
Go to Low SP

[OF] Go to Low SP QPTJUJPO

PRESS THE

Motion Inhibit
Time: 05 seconds

Press the kLFZUPEJTQMBZ


[FA] Loss of Signal
.PECVT 1SPGJCVT%FWJDFOFUPOMZ


"MMQPTJUJPOJOHDPNNBOETBSFTVCKFDUUP
BEFBECBOEUPMFSBODF
5IFEFBECBOETFUTUIFFYQFDUFE
QPTJUJPOJOHBDDVSBDZPGUIFBDUVBUPS
BOEJTEFQFOEFOUPOWBSJPVTGBDUPST
JODMVEJOH BDUVBUPSPVUQVUTQFFE 
OVNCFSPGUVSOTBOEWBMWFUPSRVF*G
UIFEFBECBOEJTTFUUPPMPXUIFWBMWF
NBZAAIVOUBSPVOEUIFTFUQPJOU
Use the + or -LFZUPEJTQMBZUIF
SFRVJSFETFUUJOH

Deadband
2.5%

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
Press the kLFZUPEJTQMBZ
[Ft] Motion Inhibit Time 

[00] to [99]UPTFDPOET

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

57

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

Use the + or -LFZUPEJTQMBZUIF


SFRVJSFETFUUJOH

KEY.

Bus System
Deadband Adjustment

<>UP<>oUPPGWBMWF
TUSPLF

Use the + or -LFZUPEJTQMBZUIF


SFRVJSFETFUUJOH

PRESS THE

Fd

Loss of Signal
Failsafe

Failsafe Action Enabled

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
Press the kLFZUPEJTQMBZ
[FF] Failsafe Action 

77

58

9.13

Option
Interrupter Timer

OJ

Setting instructions for actuator


including an interrupter timer.

When fitted, the timer will be


made available for operation.

The interrupter timer enables pulsed


iTUPQTUBSUwPQFSBUJPOCZUIFBDUVBUPS
as a response to local and remote
DPOUSPMDPNNBOET

The Interrupter cannot be


enabled or disabled using the
Setting Tool.

5IJTFGGFDUJWFMZJODSFBTFTUIFWBMWF
TUSPLFUJNFBOEDBOCFBEKVTUFEUP
QSFWFOUIZESBVMJDTIPDL XBUFSIBNNFS

BOEGMPXTVSHFTJOQJQFMJOFT
The interrupter timer is an optional
FYUSBoDIFDLXJSJOHEJBHSBNGPS
JODMVTJPO

Jd

Interrupter Timer
Enabled/Disabled

Interrupter Timer
Direction

The default for timer direction is [CL] 


UJNFSPQFSBUJPOXJMMstart in closing
and stop in openingoQVMTJOH
PQFSBUJPOBSPVOEUIFDMPTFQPTJUJPO
*GQVMTJOHPQFSBUJPOJTSFRVJSFEUPTUPQ
JODMPTJOHBOETUBSUJOPQFOJOHoBSPVOE
UIFPQFOQPTJUJPO VTFUIF+ or -LFZ

JC

Position in Valve
Closing Stroke for
Timer to Start

59

Using the + or -LFZTFMFDUUIFQPTJUJPO


for the TIMER TO START WHEN THE
VALVE IS CLOSING.
[ ] [ ] Closed 
[00] to [99]
] Open 
[

WBMWFDMPTFE
= percentage open
WBMWFPQFO

5IFEJTQMBZXJMMDIBOHFUP[OP] Opening 

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

Int. Timer
Enabled

Int. Timer
Disabled

Interrupter Timer Interrupter Timer


Disabled
Enabled

Timer Set to Start Pulsing when


Closing Valve Reaches 25% Open

8IFOUIFUJNFSPQUJPOJTBWBJMBCMFBO
additional series of settings can be
BDDFTTFECZQSFTTJOHUIFmLFZ

Timer Start
Closing

NOTE: If the timer option is not


BWBJMBCMFQSFTTJOHUIFmLFZXJMMOPU
BDDFTTTFUUJOH

Pulsed Operation Around the


Closed Position

Press the mLFZUPEJTQMBZJOUFSSVQUFS


UJNFSTFUVQTDSFFOT

Timer Start
Position: 25%

NOTE: Instructions [JC] and [JO] are


for timer operation around the Closed
QPTJUJPO'PSUJNJOHBSPVOEUIF0QFO
QPTJUJPO SFBETUPQGPSTUBSU[JC] and
start for stop [JO]

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
*GUIFUJNJOHJTOPUSFRVJSFEJOUIF
closing stroke select [JC] to [ ] [ ]WBMWF
DMPTFEQPTJUJPO
Press the kLFZUPEJTQMBZ
[JO] Timer Stop Position 

Press the kLFZUPEJTQMBZ


[JC] Timer Start Position 

JO

Position in Valve Opening


Stroke for Timer to Stop

Using the + or -LFZTFMFDUUIFQPTJUJPO


for the TIMER TO STOP WHEN THE
VALVE IS OPENING.
[ ] [ ] Closed 
[00] to [99]
[

] Open 

JF

Contactor On Time

Contactor Off Time

Using the + or -LFZTFMFDUUIFBDUVBUPS


SVOQFSJPEJOUIFSBOHFoTFDPOET

Using the + or -LFZTFMFDUUIFBDUVBUPS


TUPQQFSJPEJOUIFSBOHFoTFDPOET

Timer On Time
05 Seconds

Timer Off Time


25 Seconds

Actuator Run Period


Set for 5 Seconds

Actuator OFF Period


Set for 25 Seconds

WBMWFDMPTFE
= percentage open
WBMWFPQFO

Timer Stop
Position: 25%

Timer Set to Stop Pulsing


when Opening Valve
Reaches 25% Open

PRESS THE

Jn

KEY.

PRESS THE

KEY.

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

Press the kLFZUPEJTQMBZ


[JF] Timer Off Time 

Press the kLFZUPEJTQMBZ


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

JE

ESD Override
Interrupter Timer

5IFJOUFSSVQUFSUJNFSNBZCFPWFSSJEEFO
XIFOUIFBDUVBUPSJTVOEFS&4%TJHOBM
DPNNBOE5IJTXJMMNFBOUIFBDUVBUPS
XJMMSVOUPMJNJUXJUIPVUiTUPQTUBSUw
BDUJPOVOEFS&4%DPNNBOE
Refer to [A1] o[A3] (refer to page 36
for ESD settings)
5IFEFGBVMUGPS&4%PWFSSJEFJOUFSSVQUFS
timer is [OF] No 5IFJOUFSSVQUFSUJNFS
XJMMDPOUJOVFiTUPQTUBSUwBDUJPOEVSJOH
&4%BDUJPO
*G&4%NVTUPWFSSJEFUIFUJNFSVTFUIF

+ or -UPEJTQMBZ[On] Yes 

Timer Override
ESD: No

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
*GUJNJOHJTOPUSFRVJSFEJOUIFPQFOJOH
stroke select [JO] to [ ] [ ]

60

ESD Override Timer OFF

Press the kLFZUPEJTQMBZ


[Jn] Timer On Time 

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

78

Example
"OBDUVBUPSGJUUFEXJUIUIFJOUFSSVQUFS
UJNFSBOETFUBTUIFFYBNQMFTIPXOJO
UIFTFJOTUSVDUJPOTXPVMEPQFSBUFBU
3BUFETQFFEGSPNGVMM0QFOUP
0QFO
16SBUFETQFFEGSPN0QFOUP'VMMZ

$MPTFEBOEGSPN'VMMZ$MPTFEUP
0QFO
3BUFETQFFEGSPN0QFOUP'VMMZ
0QFO

9.14

After Power Loss [OS]

The default setting for Setting Tool


Local Control is [OF] Control Disabled 
To enable Setting Tool Control press the
+ or -LFZUPTFMFDU[On]

PRESS THE

61

9.15 Inhibit Operation

Setting Tool
Local Control [Or]

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU
8JUIUIFSFEDPOUSPMTFMFDUPSJO-PDBM 
UIF4FUUJOH5PPMDPOUSPMLFZTBSFBDUJWF
(refer to page 17)

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
SFGFSUP4FDUJPO QBHF

8IFOQSPUFDUJPOJTFOBCMFE POQPXFS
VQJGBMPXCBUUFSZJTEFUFDUFE UIF
BDUVBUPSXJMMJOIJCJUFMFDUSJDBMPQFSBUJPO
BOEEJTQMBZ1PXFS-PTT*OIJCJUWJB
BDUVBUPSBMBSNEJTQMBZ SFGFSUPQBHF

BOEUIFNPOJUPSSFMBZXJMMEFFOFSHJTF
-JNJUTNVTUSFTFUBOEUIFCBUUFSZ
SFQMBDFEoSFGFSUPQBHF
Press the kLFZUPEJTQMBZ
[OH] Close Colour 

Note
With a Folomatic option fitted and
UIF*OUFSSVQUFS5JNFSFOBCMFE UIF
Folomatic Motion Inhibit Timer must
CFBEKVTUFEUPUIFTBNFUJNFBTUIBU
set for the Interrupter Timer contactor
PGGw
'BJMVSFUPEPTPXJMMDBVTFUIFBDUVBUPS
SFTQPOTFUPEFGFSUPUIFMPXFSUJNF
XIJDINBZDBVTFDPOUSPMPSQSPDFTT
QSPCMFNT
'PSi0/wBOEi0''wUJNFTJOFYDFTTPG
TFDPOETBQQMZUP3PUPSL

9.16 Indicator LEDs


5IFDPMPVSPGUIF-&%TPOUIF*2EJTQMBZ
BSFVTFSDPOGJHVSBCMF5IFTFNFOV
TDFFOTBMMPXZPVUPTFUUIF$MPTF-&%
DPMPVSBOEUIF.JE5SBWFM-&%CFJOH
POPSPGG

I-R Tool Control


On
Power Loss
Inhibit : Off

Local Setting Tool Control Enabled

Vandal resistant actuators ONLY


SFECMBDLTFMFDUPSTOPUTVQQMJFE

'PSDPOUSPM UIFTFMFDUJPOPG[Or] Vandal
Resist JTBTGPMMPXT

5IFQSPUFDUJPONBZCFFOBCMFECZVTJOH
the + or -LFZUPTFMFDU[On]

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

[On] Local Only 


[OF] Control Disabled 
[rE] Remote Only 

OH

OU

Close LED Colour

Mid-Travel LED

The default close limit position indicator


colour is [gr] Green 

5IFEFGBVMUGPSNJEUSBWFMQPTJUJPO
indicator colour is [OF] Off 

*GSFEJOEJDBUJPOJTSFRVJSFEBUUIFDMPTF
MJNJUQPTJUJPO QSFTTUIF+ or -LFZ

*GNJEUSBWFM-&%JOEJDBUJPOJTSFRVJSFE 
press the + or -LFZ

5IFEJTQMBZXJMMDIBOHFUP[rE] Red 

5IFEJTQMBZXJMMDIBOHFUP[On] On 

PRESS THE

PRESS THE

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

indicating that it has been set

KEY.

5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHUIBUJUIBTCFFOTFU

9.17 Display Language


UL

62

Language

5IFEFGBVMUEJTQMBZUFYUMBOHVBHFJT
&OHMJTI*GUIFMBOHVBHFXBTTQFDJGJFE
BUUJNFPGPSEFSUIFBDUVBUPSXJMMCF
EFTQBUDIFEXJUIUIFTQFDJGJFEMBOHVBHF
TFU
Press the + or -LFZTUPWJFXBMUFSOBUJWF
MBOHVBHFT
"WBJMBCMFTUBOEBSEMBOHVBHFT
(FSNBODeutsch

Close Colour
Green

Mid-Travel LED
Off

French Franais
Spanish Espaol

Press the kLFZUPEJTQMBZ


[OU] Mid-Travel LED 

Press the kLFZUPEJTQMBZ


[UL] Language 

%FQFOEJOHPOUIFTQFDJGJFEMBOHVBHF 
POMZ&OHMJTIBOEPOFPUIFSNBZCF
TVQQMJFEXJUIUIFBDUVBUPS

Language
English

79

9.18

63

Default Options
[d1] and [d2]

"MM*2GVODUJPOTBSFDPOGJHVSFEUPBTFUPG3PUPSLEFGBVMU TUBOEBSE
TFUUJOHTCFGPSF
EFTQBUDI TFFUIFUBCMFPQQPTJUF8IFOSFRVFTUFE BMUFSOBUJWFTFUUJOHTTQFDJGJFE
XJUIUIFPSEFSXJMMCFVTFE8IFOTJUFDPNNJTTJPOJOHUBLFTQMBDF FOUFSFETFUUJOHT
PWFSXSJUF3PUPSLEFGBVMUTBOEUIFTFAADVSSFOUTFUUJOHTBSFVTFEGPSPQFSBUJPOBMPOH
XJUIUIFSFNBJOJOHVOBEKVTUFEEFGBVMUT
4IPVMEEJGGJDVMUZCFFODPVOUFSFEEVSJOHDPNNJTTJPOJOHUIFEFGBVMUTFUUJOHTDBOCF
SFJOTUBUFE SFUVSOJOHUIFBDUVBUPSDPOGJHVSBUJPOUPJUTPSJHJOBMNBOVGBDUVSFETUBUF
4JUFDPNNJTTJPOJOHNVTUUIFOCFHJOBHBJO
5IFSFBSFUXPMFWFMTPGEFGBVMU
d1 Rotork standard or customer specified Basic and Configuration Settings.
d2 Limit positions only factory set limits.

NOTE:



4FUUJOHTBTTPDJBUFEXJUIDPOUSPMPQUJPOT'PMPNBUJD 1BLTDBO .PECVT


1SPGJCVTBOE'PVOEBUJPO'JFMECVTBSFOPUBGGFDUFECZEPSE
'VODUJPOTXJMMSFNBJOBTTFU

Function

[d1] Default Setting

[P?]

1BTTXPSE

6OBGGFDUFEoXJMMSFNBJOBTTFU

[Ir]

*S%"o*OTJHIU

[On] 

*S%"&OBCMFE

[C]
[Cl]
[Cl]
[40]
[40] 

$MPDLXJTF
Close on Limit
Open on Limit
PGSBUFE
PGSBUFE

Basic Settings
[C1]
[C2]
[C3]
[tC] 
[tO]

$MPTF%JSFDUJPO
Close Action
Open Action
$MPTF5PSRVF
0QFO5PSRVF

Configuration Settings
[r1]
[r2]

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)

9.18

Rotork standard [d1] Default settings for IQ:

Indication Contact S1
Indication Contact S2

[CI]/[nO]$MPTF /PSNBMMZ0QFO
[OP]/[nO] 0QFO /PSNBMMZ0QFO

[r3]

Indication Contact S3

[r4]

Indication Contact S4

[CI]/[nC]$MPTF /PSNBMMZ$MPTFE
[OP]/[nC]0QFO /PSNBMMZ$MPTFE

[A1] 

&4%"DUJPO

[SP] 

4UBZQVUPO&4%

[A2]

&4%$POUBDU5ZQF

[nO]

/PSNBMMZ0QFO NBLFGPS&4%

[A3] 

&4%5IFSNPTUBU0WFSSJEF

[OF]

5IFSNPTUBUT"DUJWFEVSJOH&4%

[A4]
[A5]

&4%0WFSSJEF*OUFSMPDLT
&4%0WFSSJEF-PDBM4UPQ

[OF]
[OF] 

*OUFSMPDLT"DUJWFEVSJOH&4%
-PDBM4UPQ"DUJWFEVSJOH&4%

[A6]

Maintained Local Control

[On]

Maintains in Local Control

64

Default Options
[d1] and [d2] cont.

Rotork standard [d1] Default settings continued:

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

Function

[d1]

Default Setting

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

[A7]  XJSF3FNPUF$POUSPM
[A8] Interlocks
[A9] Conditional Control
[AE]  5PSRVF4XJUDI#ZQBTT

[SP] 
[OF] 
[OF]
[OF]

4UBZ1VUPOXJSFTJHOBM
*-GVODUJPOEJTBCMFE
Function disabled
Function disabled

To reinstate [d1]TFUUJOHT XJUI[d1]EJTQMBZFE

PRESS THE

KEY.

5IFTFUUJOHCBSTXJMMGMBTI JOEJDBUJOHUIF[d1]EFGBVMUTFUUJOHTIBWFCFFOSFJOTUBUFE

[OE]

0QUJPO&YUSB*OEJDBUJPO$POUBDUT

[OF]

6OMFTTGJUUFE4FFXJSJOHEJBHSBN

5PSFJOTUBUFGBDUPSZTFUMJNJUT BDUVBUPSQPTJUJPOFEBU
XJUI[d2]EJTQMBZFE

[OI]
[Od]

Option CPT
Remote Source

[HI]
[rE]

4mA at Closed

PRESS THE

Unless option fitted


(refer to 9.7 page 44.)

5IFTFUUJOHCBSTXJMMGMBTI JOEJDBUJOHUIF[d2]EFGBVMUMJNJUTIBWFCFFOSFJOTUBUFE

[OJ]

Option Interrupter Timer

[OF]

6OMFTTGJUUFE4FFXJSJOHEJBHSBN

[Or]

Setting Tool Local Control

[OF]

Setting Tool Control disabled

[OF]

Protection off

[OS]  1PXFS-PTT*OIJCJU

KEY.

Limits must now be reset. Refer to page 29.

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


[r5]
[r6]

Indication Contact S5

[CI]/[nO]$MPTF OPSNBMMZPQFO

Indication Contact S6

[OP]/[nO]0QFO OPSNBMMZPQFO

[r7]

[r8]


Indication Contact S7


[tI]/[nO] 5PSRVF5SJQ.JE5SBWFM

 OPSNBMMZPQFO

Indication Contact S8


[rE]/[nO]3FNPUF4FMFDUFE

 OPSNBMMZPQFO

Restore Config

[d1] Displayed

80

Reset Limits to
Range 25 Turns

[d2] Displayed

10

65

Maintenance, Monitoring
and Troubleshooting

Maintenance
&WFSZ3PUPSLBDUVBUPSIBTCFFOGVMMZ
UFTUFECFGPSFEJTQBUDIUPHJWFZFBSTPG
USPVCMFGSFFPQFSBUJPOQSPWJEJOHJUJT
JOTUBMMFE TFBMFEBOEDPNNJTTJPOFEJO
BDDPSEBODFXJUIUIFJOTUSVDUJPOTHJWFO
JOUIJTQVCMJDBUJPO
5IF*2BDUVBUPSTVOJRVFEPVCMFTFBMFE 
OPOJOUSVTJWFFODMPTVSFQSPWJEFT
complete protection for the actuator
DPNQPOFOUT
$PWFSTTIPVMEOPUCFSFNPWFEGPS
SPVUJOFJOTQFDUJPOBTUIJTNBZCF
EFUSJNFOUBMUPUIFGVUVSFSFMJBCJMJUZPG
UIFBDUVBUPS
5IFFMFDUSJDBMDPOUSPMNPEVMFDPWFSJT
CPOEFECZUIF3PUPSLRVBMJUZDPOUSPM
TFBM*UTIPVMEOPUCFSFNPWFEBTUIF
NPEVMFDPOUBJOTOPTJUFTFSWJDFBCMF
DPNQPOFOUT
"MMFMFDUSJDBMQPXFSTVQQMJFTUPUIF
BDUVBUPSNVTUCFJTPMBUFECFGPSFBOZ
maintenance or inspection is carried
PVU FYDFQUSFQMBDFNFOUPGUIFCBUUFSZ
Electrical supplies must be isolated
CFGPSFBDUVBUPSDPWFSTBSFSFNPWFE
SFGFSUP#BUUFSZSFQMBDFNFOU
JOTUSVDUJPOT

Routine maintenance should include


UIFGPMMPXJOH

WARNING:

 $IFDLBDUVBUPSUPWBMWFGJYJOHCPMUT
 GPSUJHIUOFTT
 &OTVSFWBMWFTUFNTBOEESJWFOVUTBSF
 DMFBOBOEQSPQFSMZMVCSJDBUFE
 *GUIFNPUPSJTFEWBMWFJTSBSFMZ
 PQFSBUFE BSPVUJOFPQFSBUJOH
 TDIFEVMFTIPVMECFTFUVQ
 3FQMBDFBDUVBUPSCBUUFSZFWFSZ
 ZFBST

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.
"VOJRVFDJSDVJUIBTCFFOJODPSQPSBUFE
JOUPUIFCBUUFSZGVODUJPOPGUIF*2 
FGGFDUJWFMZSFEVDJOHUIFPWFSBMMESBJO
BOETJHOJGJDBOUMZJODSFBTJOHUIFCBUUFSZ
MJGF

* Check the actuator enclosure for


 EBNBHF MPPTFPSNJTTJOHGBTUFOFST
 &OTVSFUIFSFJTOPUBOFYDFTTJWF
build up of dust or contaminant
 POUIFBDUVBUPS

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

 $IFDLGPSBOZMPTTPGMVCSJDBOU
(refer to page 78 for lubricants).

The Actuator Battery


5IFCBUUFSZTVQQPSUTUIFBDUVBUPS
position updating circuits and the
QPTJUJPO -$%
EJTQMBZXIFOUIFNBJO
QPXFSTVQQMZJTUVSOFEPGG*UFOTVSFT
the current position is updated and
EJTQMBZFEXIFONBOVBMPQFSBUJPOUBLFT
QMBDFXJUIUIFNBJOQPXFSUVSOFEPGG

#BUUFSZMFWFMTUBUVTJTJOEJDBUFECZBO
JDPOPOUIFBDUVBUPSEJTQMBZ SFGFSUP
4FDUJPO"MBSN*OEJDBUJPO(refer to
page 5)
*GUIFCBUUFSZJDPOJTEJTQMBZFEUIF
CBUUFSZNVTUCFSFQMBDFE

5IFCBUUFSZJTOPUSFRVJSFEUPSFUBJOBOZ
BDUVBUPSTFUUJOHT

10

Battery Replacement
*GUIFBDUVBUPSJTMPDBUFEXJUIJOB
IB[BSEPVTBSFBQFSNJTTJPONVTUCF
PCUBJOFEJOUIFGPSNPGBAAIPUXPSL
permit or other local regulation before
SFNPWBMBOEPSSFQMBDFNFOUPGUIF
CBUUFSZ
3FNPWBMPGUIFCBUUFSZXJUIUIFNBJO
FMFDUSJDBMQPXFSTXJUDIFEPGGXJMMSFTVMU
JOTUPSFE%BUBMPHHFSSFDPSETUJNF
reference being lost for the duration
XIFOUIFSFJTOPNBJOTBOECBUUFSZ
QPXFS*UJTUIFSFGPSFSFDPNNFOEFE
UIBUUIFCBUUFSZJTSFQMBDFEXJUIUIF
NBJOFMFDUSJDBMTVQQMZUPUIFBDUVBUPS
TXJUDIFEPO
*GNBJOFMFDUSJDBMQPXFSJTOPUBWBJMBCMF
PSJGNBJOQPXFSIBTCFFOTXJUDIFEPGG
XIJMFUIFCBUUFSZXBTEJTDIBSHFE JUJT
recommended that the actuator limits
CFDIFDLFEBGUFSCBUUFSZSFQMBDFNFOU
(refer to Section 8 Commissioning Basic
Settings, page 22)

Battery Removal
The actuator must be selected to Stop
using the red selector (refer to page 3)
"DDFTTUPUIFCBUUFSZJTWJBBMBCFMMFE
sealing plug situated on the main
HFBSDBTFOFBSUIFIBOEXIFFMIVC

66

Maintenance, Monitoring
and Troubleshooting cont.

3FNPWFUIFTFBMJOHQMVHVTJOHUIF
BQQSPQSJBUF"MMFOLFZ FOTVSJOHUIF
AA0SJOHTFBMSFNBJOTPOUIFQMVH
%JTDPOOFDUUIFCBUUFSZXJSJOHMPPN
GSPNUIFCBUUFSZUFSNJOBMT6TJOHUIF
CMBDLQVMMTUSBQ MJGUUIFCBUUFSZPVUPG
UIFSVCCFSTFBMJOHQPDLFU

*GJOEPVCUSFHBSEJOHUIFDPSSFDUCBUUFSZ
UZQF DPOUBDU3PUPSL

Fitting Replacement Battery


Fit the pull strap around the
SFQMBDFNFOUCBUUFSZBOEJOTFSUJOUP
UIFSVCCFSTFBMJOHQPDLFU3FDPOOFDU
UIFCBUUFSZXJSJOHMPPNUPUIFCBUUFSZ
UFSNJOBMT3FGJUUIFCBUUFSZTFBMJOHQMVH
ensuring O ring is in good condition
BOEDPSSFDUMZGJUUFE)BOEUJHIUFOUIF
sealing plug to 8 Nm (6 lbsft) using the
BQQSPQSJBUF"MMFOLFZ

Oil

Fig. 10.1

Battery Types
'PS&VSPQFBOIB[BSEPVTBSFBDFSUJGJFE
BDUVBUPST "5&9
VTFBO6MUSBMJGF67-
MJUIJVNNBOHBOFTFEJPYJEFCBUUFSZPOMZ
For FM and CSA certified enclosures use
BO6MUSBMJGF67-MJUIJVNNBOHBOFTF
EJPYJEFCBUUFSZ&RVJWBMFOU 6-
SFDPHOJTFE CBUUFSJFTNBZCFVTFE

6OMFTTTQFDJBMMZPSEFSFEGPSFYUSFNF
DMJNBUJDDPOEJUJPOT 3PUPSLBDUVBUPST
BSFEJTQBUDIFEXJUIHFBSDBTFTGJMMFE
XJUI4"&&1PJMXIJDIJTTVJUBCMFGPS
ambient temperatures ranging from
o'o$UP'$
*2BDUVBUPSTEPOPUSFRVJSFSFHVMBS
oil changes (refer to Weights and
Measures Section 11, page 78)

Torque and Position Monitoring


5IF*2SBOHFPGBDUVBUPSTJODPSQPSBUF
SFBMUJNF JOTUBOUBOFPVT5PSRVF
1PTJUJPONPOJUPSJOHBTTUBOEBSE
5PSRVF1PTJUJPODBOCFVTFEUP
NPOJUPSWBMWFQFSGPSNBODFEVSJOH
PQFSBUJPO5IFFGGFDUPGQSPDFTT
DIBOHFT EJGGFSFOUJBMQSFTTVSFFUD
DBO
CFFWBMVBUFE5JHIUTQPUTJOWBMWFUSBWFM
DBOCFQJOQPJOUFEBTXFMMBTHBVHJOH
UPSRVFEFWFMPQFEUISPVHITUSPLFGPS
UPSRVFWBMVFTFUUJOH(refer to pages
27, 28)
6TJOHUIF4FUUJOH5PPM UIFEJTQMBZDBO
CFTFUUPJOEJDBUF5PSRVFBOE1PTJUJPO
BTGPMMPXT
8JUIUIFBDUVBUPSEJTQMBZJOH$VSSFOU
1PTJUJPO VTJOHUIF4FUUJOH5PPM

PRESS THE m KEY.


5IFMPXFSEJTQMBZXJMMTIPXUIFUPSRVF
WBMVFBTBQFSDFOUBHFBOEBHSBQIJDBM
representation in the form of a bar
HSBQI

'PSXBUFSUJHIU 85
BDUVBUPSFODMPTVSFT
VTFBO6MUSBMJGF67-MJUIJVN
NBOHBOFTFEJPYJEFCBUUFSZPSBOZ
FRVJWBMFOU7CBUUFSZ

81

Torque = 19%
&YBNQMFTIPXT PGSBUFE
UPSRVF
BUPQFOQPTJUJPO%JTQMBZUPSRVF
range: [00] to [99]PGSBUFEUPSRVF
JOJODSFNFOUT'PSWBMVFTPGUPSRVF
BCPWFUIFEJTQMBZXJMMJOEJDBUF[HI]
%JTQMBZQPTJUJPOSBOHF
[ ] [ ]
[00] to [99]
]
[

WBMWFDMPTFE
= percentage open
WBMWFPQFO

'PSBTUBUJPOBSZBDUVBUPSUIFEJTQMBZ
XJMMJOEJDBUFUIFBDUVBMUPSRVFWBMVFBT
BQQMJFECZUIFBDUVBUPS
5PLFFQUIFUPSRVFQPTJUJPOEJTQMBZ
BDUJWFQSFTTUIF+ or -LFZT5IFEJTQMBZ
XJMMSFNBJOBDUJWFGPSBQQSPYJNBUFMZ
NJOVUFTGSPNUIFMBTULFZPQFSBUJPO

10

67

Maintenance, Monitoring
and Troubleshooting cont.

Torque Reference Profile


*2UFYUEJTQMBZNPEFMTPOMZ
0OMZWJTJCMFXIFOJO4FUUJOH.PEF4FF
4FDUJPO QBHF
5IJTGFBUVSFBMMPXTUIFVTFSUPTUPSFB
SFGFSFODFUPSRVFQSPGJMF XIJDIDBOCF
used to plan and determine periodic
NBJOUFOBODF
After commissioning has taken place
and the process is running under
OPSNBMDPOEJUJPOT BQSPGJMFPGUIFiBT
DPNNJTTJPOFEwUPSRVFNFBTVSFNFOU
PWFSUIFXIPMFTUSPLFDBOCFUBLFO
BOETUPSFEJOUIF%BUBMPHHFS5IF
TUPSFEUPSRVFSFGFSFODFQSPGJMFDBOCF
DPNQBSFEXJUIMBUFSUPSRVFQSPGJMFT
using Rotork Insight in order to
determine changes in performance of
UIFWBMWFBOEPSQSPDFTTPWFSUJNFPS
VOEFSEJGGFSFOUDPOEJUJPOT

Storing a Reference Profile


5IFMPDBUJPOPGUPSRVFSFGFSFODFQSPGJMF
[tP]TDSFFOJTTIPXOCFMPX

50

&OUFSUIFDPSSFDUQBTTXPSEBOEQSFTT
the
LFZ 1BTTXPSE$PSSFDUw
TIPVMEEJTQMBZCSJFGMZBOEUIFTFUUJOH
CBSTBQQFBS

Pressing the
LFZTUPSFTUIFMBTU
measured reference close-open and
PQFODMPTFUPSRVFQSPGJMFTXJUIJOUIF
EBUBMPHHFS

Press the kBSSPXLFZUJNFTUP


EJTQMBZUIF[tP] screen:

Press the k and mLFZTUPHFUIFSUP


SFUVSOUPUIFQPTJUJPOBMEJTQMBZ

m
50
5PSRVF

m
P?

m
cr

5IFSFGFSFODFQSPGJMFBMPOHXJUIDVSSFOU
QSPGJMFTDBOCFWJFXFEBOEBOBMZTFEVTJOH
*2*OTJHIUTPGUXBSFBTTIPXOJO'JH

Torque

PC

Configuration Settings

Ir

Torque Profile
Press
To Set

tP

*2*OTJHIUJTBWBJMBCMFGSFF WJTJU
XXXSPUPSLDPN

Basic Settings
&BDIBDUVBUPSJTTVQQMJFEXJUIPVUB
SFGFSFODFQSPGJMFTUPSFE5PTUPSFB
SFGFSFODFQSPGJMF FMFDUSJDBMMZTUSPLFUIF
BDUVBUPSVOEFSOPSNBMQSPDFTTDPOEJUJPOT
Once the reference stroke (close to
PQFOPQFOUPDMPTF
JTDPNQMFUFTUPQ
UIFBDUVBUPS
6TJOHUIFTVQQMJFE4FUUJOH5PPM QSFTT
the mBSSPXLFZUXJDFUPEJTQMBZUIF
QBTTXPSETDSFFO3FGFSUPTFDUJPO
QBHF

10

Fig. 10.2

10.1

Maintenance, Monitoring
and Troubleshooting cont.

Troubleshooting
5IF*2SBOHFPGBDUVBUPSTJTUIFXPSMET
first that can be commissioned and
JOUFSSPHBUFEXJUIPVUSFNPWJOHFMFDUSJDBM
DPWFST)FMQ4DSFFOEJBHOPTUJDTFOBCMF
fast and complete fault finding to be
DBSSJFEPVU
Question: With power on, the
actuator display is not backlit.
Position indicator lamp not
illuminated. What is wrong?
Answer:8JUINBJOTQPXFSPO UIF
BDUVBUPSTEJTQMBZTIPVMECFCBDLMJU
(refer to Section 3.3 page 4 The
Actuator Display)
$IFDLUIBUQIBTFTVQQMZJTBWBJMBCMF
BOEJTPGUIFDPSSFDUWPMUBHFBTTUBUFE
POUIFBDUVBUPSOBNFQMBUF.FBTVSF
WPMUBHFQIBTFUPQIBTFBDSPTTUFSNJOBMT
 BOEPGUIFBDUVBUPSUFSNJOBM
CVOH
Question: With power off, the
actuator does not display position.
What is wrong?
Answer:8JUINBJOTQPXFSPGGUIF
BDUVBUPSCBUUFSZTVQQPSUTQPTJUJPO
JOEJDBUJPOMJRVJEDSZTUBMEJTQMBZPOMZ

(Refer to Section 3.3 page 4 The


Actuator Display)
*GUIFEJTQMBZJTCMBOLUIFBDUVBUPS
CBUUFSZNVTUCFSFQMBDFEBOEUIFMJNJUT
PGUSBWFMSFTFU(refer to Section 10,
page 65 The Actuator Battery)

68

Setting Tool Pro


Download & Upload

Setting Tool Pro Download &


Upload
Setting Tool Pro includes a feature
XIJDIBMMPXTUIFVTFSUPFYUSBDU
BOETUPSF*2BDUVBUPSDPOGJHVSBUJPO
BOEEBUBMPHHFSGJMFTXJUIJOUIF5PPM
4UPSFEGJMFTDBOCFWJFXFEVTJOHB1$
SVOOJOH*2*OTJHIU6TJOH5IJTUPPM 
stored configuration files can also be
VQMPBEFECBDLUP*2BDUVBUPSTJOPSEFS
to replicate a setup for multiple units
MJNJUTNVTUCFTFUJOEJWJEVBMMZ


Download/Upload Menu structure

dL 01

dC 01

&YUSBDU
%BUBMPHHFS

&YUSBDU
Configuration

*2*OTJHIUJTBWBJMBCMFGSFFGSPN
XXXSPUPSLDPN
Using the new features
%BUBMPHHFSBOEDPOGJHVSBUJPOGJMFT
DBOCFFYUSBDUFEBOETUPSFEJOUIF
5PPMXJUIPVUFOUFSJOHBQBTTXPSE'PS
uploading configuration files from Tool
UPBDUVBUPS UIFBDUVBUPSTQBTTXPSE
NVTUGJSTUCFFOUFSFEDPSSFDUMZoTFF
TFDUJPO QBHFGPSEFUBJMT
Accessing the menus
5IFEPXOMPBEVQMPBENFOVTBSF
BDDFTTFEXIFOUIF4FUUJOH5PPMPro
EPXOMPBELFZmJTQSFTTFE*S%"
DPNNVOJDBUJPOJTJOJUJBMJTFE UIFHSFFO
-&%JOUIFUPPMXJOEPXXJMMGMBTI5IF
user then has 30 seconds to connect
UPUIFBDUVBUPS

82

P? Id

"DUVBUPSQBTTXPSE
entered?

Y
UC 01
Upload
Configuration

10.1

69

Setting Tool Pro


Download & Upload cont.

Downloading and storing IQ


Datalogger Files
Press the m Key
Extract Log
Extracting Data

5IFHSFFO-&%WJTJCMFJOUIFTFUUJOH5PPM
XJOEPXXJMMTUBSUGMBTIJOH
1PJOUUIF5PPMBUUIFBDUVBUPS%JTQMBZ
Once communication has been
TVDDFTTGVMMZFTUBCMJTIFE UIF&YUSBDU
%BUBMPHHFSTDSFFOXJMMCFEJTQMBZFE

Extract Log
Memory Loc: 01

Extract Datalogger screen


Note.*2BDUVBUPSTXJUIOPOUFYU
EJTQMBZTTIPXDPEFTZNCPMTPOMZ
5IFTDSFFOXJMMEFGBVMUUP.FNPSZ
-PDBUJPO5IFSFBSFBUPUBMPG
GPVSNFNPSZMPDBUJPOTBWBJMBCMFGPS
EBUBMPHHFST XIJDIBSFTFMFDUFECZ
pressing the + or LFZT

Downloading and storing IQ


Configuration Files

Note.*2BDUVBUPSTXJUIOPOUFYU
EJTQMBZTTIPXDPEFTZNCPMTPOMZ

Press the m Key

5IFTDSFFOXJMMEFGBVMUUP.FNPSZ
-PDBUJPO5IFSFBSFBUPUBMPG
UFONFNPSZMPDBUJPOTBWBJMBCMFGPS
$POGJHVSBUJPO'JMFT XIJDIBSFTFMFDUFE
CZQSFTTJOHUIF+ or LFZT

5IFHSFFO-&%WJTJCMFJOUIFTFUUJOH5PPM
XJOEPXXJMMTUBSUGMBTIJOH
1PJOUUIF5PPMBUUIFBDUVBUPS%JTQMBZ

Extracting Log screen

Once communication has been


TVDDFTTGVMMZFTUBCMJTIFE UIF&YUSBDU
%BUBMPHHFSTDSFFOXJMMCFEJTQMBZFE

Note.*2BDUVBUPSTXJUIOPOUFYU
EJTQMBZTTIPXDPEFTZNCPMTPOMZ
5IFFYUSBDUJPOUBLFTBQQSPYJNBUFMZ
seconds for a full datalogger (2 minutes
GPSOPOUFYUEJTQMBZT
"GUFSBTVDDFTTGVM
FYUSBDUJPO UIFTDSFFOXJMMSFWFSUUP
UIF&YUSBDU-PHTDSFFO*GEVSJOHUIF
EPXOMPBEJOHBOFSSPSJTFODPVOUFSFE 
[dL Er] XJMMCFEJTQMBZFEBMPOHXJUI
Error XBJUGPSUIFTDSFFOUPSFWFSUUP
[dL 01]BOEUSZBHBJO

Extract Log
Memory Loc: 01

Extract Datalogger screen


Note.*2BDUVBUPSTXJUIOPOUFYU
EJTQMBZTTIPXDPEFTZNCPMTPOMZ

The action of downloading the


actuator datalogger file will
automatically download the
configuration file to the Tool.

PRESS THE

8IFOUIFSFRVJSFEMPDBUJPOIBTCFFO
LFZUPJOJUJBUF
TFMFDUFE QSFTTUIF
UIFFYUSBDUJPO5IFGPMMPXJOHTDSFFOXJMM
CFEJTQMBZFE

10.1

k KEY.

5IFGPMMPXJOHTDSFFOXJMMCFEJTQMBZFE

Extract Config
Memory Loc: 01

PRESS THE

Note: Actuator must be set to


Local when writing configuration
data.

PRESS THE

For access to the Upload Configuration


TDSFFO UIFBDUVBUPSTQBTTXPSENVTU
GJSTUCFTFUDPSSFDUMZ TFFTFDUJPO
Press the m Key

k KEY.

5IFEPXOMPBEDPOGJHVSBUJPOTDSFFOXJMM
CFEJTQMBZFE[dC 01]

m KEY.

5IFVQMPBEDPOGJHVSBUJPOTDSFFOXJMMCF
EJTQMBZFE

Note. *2BDUVBUPSTXJUIOPOUFYU
EJTQMBZTTIPXDPEFTZNCPMTPOMZ
5IFXSJUJOHQSPDFTTUBLFBQQSPYJNBUFMZ
TFDPOETUPDPNQMFUF BGUFSXIJDI
UIFTDSFFOSFWFSUTUPUIF6QMPBEJOH
$POGJHVSBUJPOTDSFFO*GEVSJOHUIF
XSJUJOHQSPDFTTBOFSSPSJTFODPVOUFSFE 
[dL Er]XJMMCFEJTQMBZFEBMPOHXJUI
Error XBJUGPSTFDPOETVOUJMUIF
TDSFFOSFWFSUTUP[UC 01]BOEUSZBHBJO

Write Config
Memory Loc: 01

Upload Configuration screen


Note.*2BDUVBUPSTXJUIOPOUFYU
EJTQMBZTTIPXDPEFTZNCPMTPOMZ
Using the + or LFZT TFMFDUUIF
NFNPSZMPDBUJPOXIFSFUIFSFRVJSFE
configuration file is stored and press
LFZ UIFGPMMPXJOHTDSFFOXJMM
the
CFEJTQMBZFE

5IFHSFFO-&%WJTJCMFJOUIFTFUUJOH5PPM
XJOEPXXJMMTUBSUGMBTIJOH
1PJOUUIF5PPMBUUIFBDUVBUPS%JTQMBZ
0ODFDPNNVOJDBUJPOIBTCFFOTVDDFTTGVMMZ
FTUBCMJTIFE UIFEPXOMPBEEBUBMPHHFS
TDSFFOXJMMCFEJTQMBZFE[dL 01]

Extracting Configuration screen


Note. *2BDUVBUPSTXJUIOPOUFYU
EJTQMBZTTIPXDPEFTZNCPMTPOMZ
5IFFYUSBDUJPOUBLFTBQQSPYJNBUFMZ
TFDPOET"GUFSBTVDDFTTGVMFYUSBDUJPO 
UIFTDSFFOXJMMSFWFSUUPUIF&YUSBDU
DPOGJHVSBUJPOTDSFFO*GEVSJOHUIF
EPXOMPBEJOHBOFSSPSJTFODPVOUFSFE 
[dL Er]XJMMCFEJTQMBZFEBMPOHXJUI
Error, XBJUGPSTFDPOETVOUJMUIFTDSFFO
SFWFSUTUP[dC 01]BOEUSZBHBJO

70

Uploading a configuration File to an


IQ actuator

Open and close limit positions and


current position are not copied
and must be set on each individual
actuator.3FGFSUPTFDUJPO

Extract Config
Extracting Data

Extract Configuration screen

Setting Tool Pro


Download & Upload cont.

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.
3FGFSUPTFDUJPOT

8IFOUIFSFRVJSFEMPDBUJPOIBTCFFO
TFMFDUFE QSFTTUIF
LFZUPJOJUJBUF
UIFFYUSBDUJPO5IFGPMMPXJOHTDSFFOXJMM
CFEJTQMBZFE

Write Config
Writing Data

Uploading Configuration screen

83

10.2 Help Screens


8JUIUIFBDUVBUPSQPXFSFEVQBOE
-PDBMPS4UPQTFMFDUFE FJHIU)FMQ
Screens can be accessed using the
Setting Tool (refer to Fig. 9.1 page 32
for their location)
With Remote selected press the m
LFZPOUIF4FUUJOH5PPMUXJDF5IF)FMQ
4DSFFOTXJMMCFEJTQMBZFE
Each screen uses bars to indicate
the status of a particular control or
JOEJDBUJPOGVODUJPO&BDICBSSFBDUTUP
changes in the status of its actuator
GVODUJPOCZUVSOJOHAAPOPSAAPGG

H1

H1

'PSUSPVCMFTIPPUJOH BDDFTTUIF
GPMMPXJOH)FMQ4DSFFOTBOESFGFSUP
UFYU

Phase
Loss

H1o'BDUPSTJOIJCJUJOHFMFDUSJDBM

PQFSBUJPO

H4o.POJUPSSFNPUFDPOUSPMJOQVUTUP

UIFBDUVBUPS
H5o.POJUPSSFNPUFJOUFSMPDLTMPDBM
control inputs and motor

UIFSNPTUBUT




-PX
#BUUFSZ

&4%
"DUJWF

5IFCBUUFSZTIPVMECFSFQMBDFEBUUIF
FBSMJFTUPQQPSUVOJUZ(refer to page 65)

LOCAL CONTROLS ERROR


Bar ON = Invalid Local Control
Signals Detected.

 #BUUFSZ-PX
on
 1PXFSVQ

POSITION ERROR

H7o.POJUPSUSBWFMMJNJUT DFOUSF

DPMVNOBOEQPTJUJPOMJNJUTUBUVT

%VSJOHQPXFSVQUIFBDUVBUPSQPTJUJPO
processor compares the current position
UPUIBUTUPSFEJOUIF&FQSPN*GUIFSFJT
BEJTDSFQBODZUIJTJTTIPXOBTBDVSSFOU
QPTJUJPOFSSPS

Bar ON = Current Position Error


Present.

H3

PHASE LOSS
Bar ON = Phase Lost (3 Phase
Actuators Only).
-PTTPGUIJSENPOJUPSFEQPXFSTVQQMZ
QIBTFDPOOFDUFEUPBDUVBUPSUFSNJOBM

H4

Actuator Limit and


Fault Status

Remote Control
Inputs

H3

LOW BATTERY
Bar ON = Battery level low.
Bar OFF = Battery OK.
#BS0/XIFOUIFCBUUFSZJTMPXCVUTUJMM
BCMFUPTVQQPSUUIFOFDFTTBSZBDUVBUPS
GVODUJPOT

$MPDLXJTF
Limit

Anti
$MPDLXJTF
Limit

Remote
Maintain 2

Remote
Open 1

&4%

3FNPUF
Close 1

Remote
$MPTF

&4%

Remote
Open 2

Remote
Maintain 1

Inhibit

ESD SIGNAL ACTIVE

72

H4

5IFCBUUFSZTIPVMECFSFQMBDFEBUUIF
FBSMJFTUQPTTJCMFPQQPSUVOJUZ

 #BUUFSZ
%JTDIBSHFE

'PSFYBNQMFJGB-PDBM0QFOBOE$MPTF
signal is detected at the same time this
XPVMECFDMBTTFEBTBOJOWBMJEPSGBVMU
DPOEJUJPO

Re-setting of both actuator limits


TIPVMEOPXCFDBSSJFEPVU(refer to
page 29)

Battery Level and


ESD Control Input




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


UIFBDUVBUPSPQFSBUJPOXJMMCFJOIJCJUFE
XIFOQPXFSFEVQXJUIBEJTDIBSHFE
CBUUFSZ(refer to [OS] page 61).

H6o.POJUPSUPSRVFTXJUDITUBUVTBOE
IR Setting Tool communication for

WBOEBMQSPPGBQQMJDBUJPOT

)FMQTDSFFOCBSTTIPXO
BSFVOEFGJOFEBOENBZ
CF0/ 0''PSGMBTIJOH




Position
Error

)FMQ4DSFFO

H9o3PUPSLVTFPOMZ

H2

Bar ON = Low battery detected On


Power Up.

Local
Controls
Error

H8o.POJUPSUIFBDUVBUPSTQPTJUJPO

TFOTJOHEFWJDFT

H2

BATTERY LOW ON POWER UP

H2o.POJUPSCBUUFSZMFWFMBOE&4%

DPOUSPMJOQVU
H3o.POJUPSUIFQPTJUJPOMJNJUBOE

BDUVBUPSQPXFSTVQQMZTUBUVT

71

Factors Inhibiting
Electrical Operation

Bar ON = ESD Signal is present.


)FMQ4DSFFO

BATTERY DISCHARGED
Bar ON = Battery Discharged.
#BS0/XIFOUIFCBUUFSZJTOPMPOHFS
able to support actuator functions
VOEFSMPTTPGQPXFSDPOEJUJPOT
5IFCBUUFSZNVTUCFSFQMBDFE(refer to
Section 10 page 65) and limit positions
reset (refer to [LC] and [LO] page 29)

8IFOBQQMJFE BO&NFSHFODZ4IVUEPXO
4JHOBMXJMMPWFSSJEFBOZFYJTUJOHMPDBM
PSSFNPUFDPOUSPMTJHOBM DBVTJOHUIF
actuator to respond in the direction
TFMFDUFEGPS&4%
5IF&4%GVODUJPOXJMMCFEFUFSNJOFE
CZUIFTFUUJOHTPO$POUSPM.PEF
Configuration screens [A1] to [A5]
(refer to Section 9.3 page 36)
5IFBDUVBUPSXJMMOPUSFTQPOEUPBOZ
MPDBMPSSFNPUFDPOUSPMXIJMFBO&4%
TJHOBMJTNBJOUBJOFE

)FMQ4DSFFO

CLOCKWISE LIMIT

)FMQ4DSFFO

Bar ON = Actuator has reached


clockwise limit of travel.

"MMSFNPUFTJHOBMTEFTJHOBUFEXJUIA
BSFTUBOEBSEIBSEXJSFESFNPUFJOQVUT

ANTI-CLOCKWISE LIMIT

8IFOB1BLTDBO 1SPGJCVTPS
'PVOEBUJPO'JFMECVTDBSEJTGJUUFE 
remote control inputs are designated
XJUIBA

Bar ON = Actuator has reached


Anti-clockwise limit.

INHIBIT
Bar ON = Actuator inhibited.

Possible Causes:

REMOTE OPEN 1
Bar OFF = Remote Open Signal
Present.

1IBTF-PTT QIBTFPOMZ

1PXFS-PTT*OIJCJU QBHF

*OUFSOBM'BJMVSF

continued...

84

H4

Remote Control
Inputs continued

H5

H5

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

REMOTE MAINTAIN 1
Bar OFF = Remote Maintain
signal present.
Bar ON = Remote Maintain not
present and/or Remote Stop
active.

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

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

ESD 2
Bar OFF = ESD signal present
from BUS option pcb.

REMOTE MAINTAIN 2
Bar OFF = Remote Maintain
signal present from BUS option
pcb.

Local Stop
not
Selected

Open
Interlock

CLOSE INTERLOCK

THERMOSTAT TRIPPED

Bar ON = Close Interlock Active.


(Actuator disabled)

Bar ON = Thermostat tripped.


5IFBDUVBUPSNPUPSJTQSPUFDUFECZ
UIFSNPTUBUT

Thermostat
Tripped

Close
Interlock

Unauthorised Close electrical operation


DBOCFQSFWFOUFECZJOUFSMPDLJOH
UIFBDUVBUPS $MPTF
DPOUSPMXJUIBO
FYUFSOBMJOUFSMPDLDPOUBDU

Local Open
not Present

Local not
Selected

*GFYUFSOBMJOUFSMPDLTBSFOPUSFRVJSFE
the interlock function must be selected
0''

4IPVMEUIFNPUPSCFDPNFPWFSIFBUFE
UIFUIFSNPTUBUTXJMMUSJQBOEUIF
BDUVBUPSXJMMTUPQ0ODPPMJOHUIF
UIFSNPTUBUXJMMBVUPNBUJDBMMZSFTFU 
FOBCMJOHPQFSBUJPO4FFUIFBDUVBUPS
OBNFQMBUFGPSUIFNPUPSSBUJOH

REMOTE NOT SELECTED

LOCAL STOP NOT SELECTED

Bar ON = Remote control not selected.


Bar OFF = Remote control selected.

Bar ON = Local Stop not selected.


Bar OFF = Local stop selected.

LOCAL CLOSE NOT PRESENT

LOCAL NOT SELECTED

Bar ON = Local Close signal not present.


Bar OFF = Local Close signal present.

Bar ON = Local control not selected.


Bar OFF = Local control selected.

Local Close
not
Present

Remote
not
Selected

)FMQ4DSFFO

OPEN INTERLOCK
Bar ON = Open Interlock Active.
(Actutator disabled)
Unauthorised Open electrical operation
DBOCFQSFWFOUFECZJOUFSMPDLJOH
UIFBDUVBUPS 0QFO
DPOUSPMXJUIBO
FYUFSOBMJOUFSMPDLDPOUBDU

LOCAL OPEN NOT PRESENT


Bar ON = Local Open signal not present.
Bar OFF = Local Open signal present.

*GFYUFSOBMJOUFSMPDLTBSFOPUSFRVJSFE
the interlock function must be selected
0''

Torque Switch Status & IR


Setting Tool Comms for
Vandal Proof Applications

H6

H6

IR Remote
Control not
Selected
IR Local
Control
 %JTBCMFE

Local
Controls
OPU'JUUFE




*30QFO
4JHOBMOPU
Present

5PSRVF
4XJUDI
Tripped

)FMQ4DSFFO
When actuators are supplied for
7BOEBM1SPPGBQQMJDBUJPOTUIFMPDBM
DPOUSPMLOPCTBSFSFNPWFEUPQSFWFOU
VOBVUIPSJTFEPQFSBUJPO
The local control functions are then
DBSSJFEPVUCZVTJOHUIF*OGSBSFE
4FUUJOH5PPM

Travel Limits, Centre


Column & Remote
Indication Outputs

H7
TORQUE SWITCH TRIPPED

IR OPEN SIGNAL NOT PRESENT

Bar ON = Torque switch tripped.

Bar OFF = IR Open signal present.

8IFOUIFBDUVBUPSHFOFSBUFTBWBMVF
PGUPSRVFFRVBMUPUIBUTFUGPS0QFO
XIFOPQFOJOH
PS$MPTF XIFODMPTJOH

JUXJMMTUPQ QSPUFDUJOHJUTFMGBOEUIF
WBMWFGSPNEBNBHF5IJTGFBUVSFJT
LOPXOBT0WFS5PSRVF1SPUFDUJPO

IR CLOSE SIGNAL NOT PRESENT

0ODFBUPSRVFUSJQIBTPDDVSSFEGVSUIFS
PQFSBUJPO*/5)&4".&%*3&$5*0/JT
QSFWFOUFE

IR Closed
Signal not
Present



73

Remote Interlocks,
Local Control
Inputs, & T/stat

5IJTAAMBUDIJOHPGUIFFWFOUQSPUFDUT
UIFBDUVBUPSBOEWBMWFGSPNSFQFBUFE
hammering against the obstruction
as a response to a maintained control
TJHOBM
To de-latch the actuator it must be
SFWFSTFE
(For actuator torque adjustment, refer
to [tC ] and [tO] pages 27 and 28)

H7
3FMBZ

Open
-JNJU

3FMBZ

3FMBZ

Bar OFF = IR Close signal present.

IR LOCAL CONTROL DISABLED

Bar OFF = IR Local control enabled.


5PPQFSBUFUIFBDUVBUPSMPDBMMZXJUI
the IR Setting Tool refer to the option
selection screen [Or]4FDUJPO 
QBHF
[Or] must be selected to [On]

Ir REMOTE CONTROL NOT


SELECTED

74

$MPTF
Limit
Actuator
.PWJOH

3FMBZ

)FMQ4DSFFO

OPEN LIMIT

Bar OFF = Ir Remote control selected


WBOEBMQSPPGVOJUTPOMZ


Bar ON = Actuator has reached


open limit.

8IFOBDUVBUPSJTTVQQMJFEXJUIPVUMPDBM
DPOUSPMTGPSWBOEBMQSPPGBQQMJDBUJPOT
the option selection screen [Or] must
be set to [rE] for Remote operation
(refer to Section 9.14 page 61)

CLOSE LIMIT
Bar ON = Actuator has reached
Close limit.

ACTUATOR MOVING
Bar ON = Actuator moving.

LOCAL CONTROLS NOT FITTED


Bar OFF = Local controls fitted
(standard).
Bar ON = Local controls not fitted
(vandal proof).

SWITCH CONTACTS S1, S2, S3, S4


Bar ON = S contact is close circuit.
#BSJOEJDBUJPOJTSFBMUJNFBOESFBDUJWF
(refer to Section 9.2 [r1] page 34 for
configuration of Scontacts)

85

H8

75

Actuator Position
Sensing Devices

H8

8IFOUIFNPUPSJTSVOOJOH 0/BOE
0''CJUEVSBUJPOTIPVMECFFRVBM
'PSUIFUXPTFOTPST "BOE# DPSSFDU
PQFSBUJPOJTJOEJDBUFECZUIFGPMMPXJOH
USVUIUBCMF

Position
Sensor A
Position
Sensor B

5PPCTFSWFUIJTGVODUJPO TFMFDUNBOVBM
operation and turn the actuator
IBOEXIFFMDMPDLXJTF TUBSUJOHXJUIBMM
sensors OFF:


)FMQ4DSFFO

POSITION SENSOR A
4FOTFTPVUQVUSPUBUJPO6TFEGPS
UIFQPTJUJPOTFOTJOHDJSDVJU$PSSFDU
PQFSBUJPOPGUIFTFOTPSJTJOEJDBUFECZ
the bar being ON (and OFF) 12 times
QFSPVUQVUSFWPMVUJPO8IFOUIFNPUPS
JTSVOOJOH 0/BOE0''CJUEVSBUJPO
TIPVMECFFRVBM

$-0$,8*4&%FH

Sensor B

Sensor A

POSITION SENSOR B
4FOTFTPVUQVUSPUBUJPO6TFEGPS
UIFQPTJUJPOTFOTJOHDJSDVJU$PSSFDU
PQFSBUJPOPGUIFTFOTPSJTJOEJDBUFECZ
the bar being ON (and OFF) 12 times
QFSPVUQVUSFWPMVUJPO

10.3

76

IQ Infrared
Diagnostic and Configuration

*2BDUVBUPSTJODMVEFBO*S%" *OGSBSFE
%BUB"TTPDJBUJPO
JOUFSGBDFBTTUBOEBSE 
BMMPXJOHOPOJOUSVTJWFEJBHOPTUJDT 
BOBMZTJTBOEDPOGJHVSBUJPO
*2*OTJHIUTPGUXBSFUPPMGPS1$BOE*2
1PDLFU*OTJHIUGPS1%" 1FSTPOBM%JHJUBM
"TTJTUBOU
IBWFCFFOEFWFMPQFEUP
enable the actuator configuration and
onboard datalogger to be reconfigured
BOEBOBMZTFE"1$SVOOJOH*2*OTJHIU
TPGUXBSFPS1%"SVOOJOH*21PDLFU
Insight can be used to interrogate the
BDUVBUPSWJBOPOJOUSVTJWFJOGSBSFE*S%"
DPNNVOJDBUJPO7JTJUXXXSPUPSLDPN
GPSJOGPSNBUJPO
"MUFSOBUJWFMZ UIFJOUSJOTJDBMMZTBGF
Rotork Setting Tool ProBMMPXTUIF
VTFSUPFYUSBDUBOETUPSF*2BDUVBUPS
configuration and datalogger files
XJUIJOUIF5PPM4UPSFEGJMFTDBOCF
VQMPBEFEPWFSBO*S%"o64#JOUFSGBDF
UPB1$SVOOJOH3PUPSL*2*OTJHIU
XIFSFUIFZDBOCFWJFXFE BOBMZTFE
BOETUPSFEJOBTBGF DMFBOFOWJSPONFOU
Using the Setting Tool Pro BDUVBUPSTFU
VQDBOCFDPOGJHVSFEPOUIF1$ TUPSFE
JOUIFUPPM USBOTQPSUFEUPUIFBDUVBUPS
BOEVQMPBEFE5IFUPPMDBOUSBOTGFS
the same configuration to multiple
BDUVBUPSTXIFSFBDUVBUPSTFUVQJTUIF
TBNF3FGFSUPQBHF

To enable communication with IQ


Insight the actuator IrDA interface
must be enabled.
5IFEFGBVMUTFUUJOHGPS*2*S%"JT[On] 
FOBCMJOH*S%"
5PEJTBCMF*S%"BOEQSFWFOU*S%"BDDFTT 
use the + or LFZ5IFEJTQMBZXJMM
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
QBHF


5IFEJTQMBZFEPQUJPOXJMMGMBTI TUPSFE

JOEJDBUJOHJUIBTCFFOTFU

IrDA Comms
Enabled

*2*OTJHIUBOE*21PDLFU*OTJHIU
TPGUXBSFBSFBWBJMBCMFGSFFPGDIBSHF
GSPNUIF3PUPSLXFCTJUF
XXXSPUPSLDPN
"LJUJTBWBJMBCMFGSPN3PUPSL XIJDI
JODMVEFTBO*S%"64#BEBQUFSBOE
ESJWFSTGPSDPOOFDUJPOUPB1$5IF,JU
BMTPJODMVEFT*2*OTJHIUTPGUXBSF1%"
DPNNVOJDBUJPOJTWJBUIFJOUFSOBM*S%"QPSU

86

77

10.4 Environmental
End user advice on disposal at end of life of the product
Subject

Definition

Remarks / examples

Hazardous

Recyclable

EU Waste Code

#BUUFSJFT



-JUIJVN
"MLBMJOF
-FBE"DJE

*2*25TUBOECZCBUUFSZ
4FUUJOHUPPM
#BUUFSZ'BJMTBGF6OJUT

:FT
:FT
:FT

:FT
:FT
:FT





8JMMSFRVJSFTQFDJBMUSFBUNFOUCFGPSF
EJTQPTBM VTFETQFDJBMJTUSFDZDMFSTPS
XBTUFEJTQPTBMDPNQBOJFT

&MFDUSJDBM
&MFDUSPOJD
&RVJQNFOU

1SJOUFEDJSDVJUCPBSET
8JSF

"MM1SPEVDUT
"MM1SPEVDUT

:FT
:FT

:FT
:FT




6TFTQFDJBMJTUSFDZDMFST

(MBTT

-FOT8JOEPX

$FOFMFD2VBMJGJFE*2*25"3BOHF1SJTN

/P

:FT



6TFTQFDJBMJTUSFDZDMFST

.FUBMT





"MVNJOJVN
$PQQFS#SBTT
;JOD
*SPO4UFFM
.JYFE.FUBMT

(FBSDBTFTBOEDPWFSTNPTUQSPEVDUT
8JSF *2DPMVNOT OPUBMMTJ[FT
NPUPSXJOEJOHT
*2DMVUDI3JOHBOEBTTPDJBUFEDPNQPOFOUT
(FBSTBOE(FBSDBTFT "3BOHFBOEMBSHFS*2

*2NPUPSSPUPST

/P
/P
/P
/P
/P

:FT
:FT
:FT
:FT
:FT







6TFMJDFOTFESFDZDMFST

1MBTUJDT


(MBTTGJMMFEOZMPO
6OGJMMFE

$PWFST *25DMVUDIDPNQPOFOUT FMFDUSPOJDTDIBTTJT


(FBST

/P
/P

/P
:FT




%JTQPTBMBTHFOFSBMDPNFSDJBMXBTUF
6TFTQFDJBMJTUSFDZDMFST

Oil (SFBTF



.JOFSBM,FSPTFOF.JYFE
.JOFSBM
'PPE(SBEF
(SFBTF

(FBSCPYMVCSJDBUJPO
:FT
:FT

(FBSCPYMVCSJDBUJPO
:FT
:FT

(FBSCPYMVCSJDBUJPO
:FT
:FT

4JEF)BOEXIFFM  MJOFBSESJWF:FT/P

8JMMSFRVJSFTQFDJBMUSFBUNFOUCFGPSF
EJTQPTBM VTFTQFDJBMJTUSFDZDMFSTPS
XBTUFEJTQPTBMDPNQBOJFT

3VCCFS


4FBMT0SJOHT


$PWFSBOETIBGUTFBMJOH


.BZSFRVJSFTQFDJBMUSFBUNFOUCFGPSF
EJTQPTBM VTFTQFDJBMJTUXBTUFEJTQPTBM
companies

:FT


/P





Disposal

In all cases check local authority regulation before disposal

11

78

Weights and Measures

Oil

Actuator Size

Nett Weight *
kg/lbs

Oil Capacity
litres/pt.-US

*2





*2





*2





Grease

*2





Side handwheels.
&YUSFNFQSFTTVSFNVMUJQVSQPTFHSFBTF
.6-5*4.4PSFRVJWBMFOU'PSMPX
temperatures use a grease suitable for
use at -60DTVDIBT0QUJUFNQ55*&1
Linear drive unit.
&YUSFNFQSFTTVSFNVMUJQVSQPTFHSFBTF
.6-5*4.4PSFRVJWBMFOU

*2





*2





*2





*2





*2





*2





'PPEHSBEFMVCSJDBUJOHPJMJTBWBJMBCMFBT
BOBMUFSOBUJWFDPOUBDU3PUPSL

*2





6OMFTTTQFDJBMMZPSEFSFEGPSFYUSFNF
DMJNBUJDDPOEJUJPOT 3PUPSLBDUVBUPST
BSFEJTQBUDIFEXJUIHFBSDBTFTGJMMFE
XJUI4"&&1PJMTVJUBCMFGPSBNCJFOU
UFNQFSBUVSFTSBOHJOHGSPNo'
o$UP'$

* NOTE:&YDMVEFTTFDPOETUBHF
HFBSCPYJGGJUUFE

87

79

BHD Binary, Hexadecimal and


Decimal Conversion Table
BINARY

HEX DEC

BINARY

HEX DEC

BINARY

HEX DEC

BINARY

HEX DEC

BINARY

HEX DEC

BINARY

HEX DEC

BINARY

HEX DEC

BINARY

HEX DEC

0000 0000

00

0010 0000

20

32

0100 0000

40

64

  



1000 0000

128

1010 0000

A0

160

  $ 

1110 0000

E0

224

0000 0001

01

0010 0001

21

33

0100 0001

41

65

 





   

1010 0001

A1

161

  $ 

1110 0001

E1

225

0000 0010

02

0010 0010

22

34

0100 0010

42

66

 





1000 0010

82

130

1010 0010

A2

162

  $ 

1110 0010

E2

226

1110 0011

E3

227

E4

228

0000 0011

03

0010 0011

23

80

35

0100 0011

43

67

 

 

1000 0011

83

131

1010 0011

A3

163

  $ 

44

68

0110 0100

64 100

1000 0100

84

132

1010 0100

A4

164

  $ 

1110 0100

0000 0100

04

0010 0100

24

36

0100 0100

0000 0101

05

0010 0101

25

37

  



0110 0101

65 101

1000 0101

85

133

1010 0101

A5

165

  $ 

  & 

0000 0110

06

0010 0110

26

38

0100 0110

46

70

0110 0110

66 102

1000 0110

86

134

1010 0110

A6

166

  $ 

1110 0110

E6

230

0000 0111

07

  



0100 0111

47

71

0110 0111

67 103

1000 0111

87

135

1010 0111

A7

167

  $ 

1110 0111

E7

231

0000 1000

08

0010 1000

40

0100 1000

48

72

0110 1000

68 104

1000 1000

88

136

1010 1000

A8

168

1100 1000

1110 1000

E8

232

  



  



 

 

   

  " 

  $ 

  & 

  

28

C8

200

0000 1010

0A

10

0010 1010

2A

42

0100 1010

4A

74

0110 1010

6A 106

1000 1010

138

1010 1010

AA 170

1100 1010

CA 202

1110 1010

EA

234

0000 1011

0B

11

0010 1011

2B

43

0100 1011

4B

75

0110 1011

6B 107

  # 

1010 1011

AB

171

1100 1011

CB

203

1110 1011

EB

235

0000 1100

0C

12

0010 1100

2C

44

0100 1100

4C

76

0110 1100

6C 108

1000 1100

1010 1100

AC 172

1100 1100

CC 204

1110 1100

EC

236

8C

140

  % 

  "% 

  $% 

  &% 

6E 110

1000 1110

8E

142

1010 1110

AE

174

1100 1110

CE

206

1110 1110

EE

6F 111

1000 1111

8F

143

1010 1111

AF

175

1100 1111

CF

207

 

&' 

0111 0000

70 112

   

1011 0000

B0

176

  % 

1111 0000

F0

240

0111 0001

71 113

   

1011 0001

B1

177

  % 

1111 0001

F1

241

82

0111 0010

72 114

   

1011 0010

B2

178

  % 

1111 0010

F2

242

  % 

1111 0011

F3

243

  % 

  % 

  % 

 

% 

0000 1110

0E

14

0010 1110

2E

46

0100 1110

4E

78

0110 1110

0000 1111

0F

15

0010 1111

2F

47

 

'



0110 1111

0001 0000

10

16

0011 0000

30

48

0101 0000

50

80

0001 0001

11

17

  



0101 0001

51

81

0001 0010

12

18

0011 0010

50

0101 0010

52

32

8A

238

  



0011 0011

33

51

0101 0011

53

83

0111 0011

73 115

   

  # 

0001 0100

14

20

0011 0100

34

52

0101 0100

54

84

0111 0100

74 116

   

1011 0100

B4

180

  % 

1111 0100

F4

244

0001 0101

15

21

0011 0101

35

53

0101 0101

55

85

0111 0101

75 117

   

1011 0101

B5

181

  % 

1111 0101

F5

245

0001 0110

16

22

0011 0110

36

54

0101 0110

56

86

0111 0110

76

118

   

1011 0110

B6

182

  % 

1111 0110

F6

246

0001 0111

17

23

0011 0111

37

55

0101 0111

57

87

   

   

1011 0111

B7

183

  % 

1111 0111

F7

247

0001 1000

18

24

0011 1000

38

56

0101 1000

58

88

0111 1000

120

   

1011 1000

B8

184

  % 

1111 1000

F8

248

  



  



  



   

   

  # 

  % 

 

' 

0001 1010

1A

26

0011 1010

58

  " 

0111 1010

7A

122

  " 

1011 1010

BA

186

  %" 

1111 1010

FA

250

0001 1011

1B

27

  #



  #



0111 1011

7B

123

  # 

1011 1011

BB

187

  %# 

1111 1011

FB

251

0001 1100

1C

28

0011 1100

60

  $ 

0111 1100

7C

124

  $ 

1011 1100

BC

188

  %$ 

1111 1100

FC

252

  % 

  % 

  % 

  % 

  % 

  #% 

  %% 

  '% 

0001 1110

1E

30

0011 1110

3E

62

  &



0111 1110

7E

126

  & 

  #& 

 

%& 

1111 1110

FE

254

0001 1111

1F

31

0011 1111

3F

63

 



0111 1111

7F

127

 

 

  %' 

1111 1111

FF

255

12

3A
3C

'

78

' 

#' 

80

IQ Approvals

Refer to actuator nameplate for unit specific approval details


European Hazardous area
EExd IIB T4. ATEX (94/9/EC) II 2GD
5FNQFSBUVSF$UP $ 'UP '

0QUJPO$UP $ 'UP '

0QUJPO$UP $ 'UP '

0QUJPO$UP $ 'UP '


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

International Hazardous area


IECEx. Exd IIB T4
*&$BOE*&$GPS&YE**#5
Temperature -20C to +60C (-4F to +140F)
0QUJPO$UP $ 'UP '

0QUJPO$UP $ 'UP '

0QUJPO$UP $ 'UP '


5FNQFSBUVSF$UP $ 'UP '



0QUJPO$UP $ 'UP '

0QUJPO$UP $ 'UP '

0QUJPO$UP $ 'UP '


IECEx. Exd IIC T4

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

USA hazardous Area


FM. Class I, Division 1, Groups C & D, Class II,
Division 1, Groups E, F & G.

5FNQFSBUVSF$UP$ 'UP '



0QUJPO$UP $ 'UP '

0QUJPO$UP $ 'UP '

0QUJPO$UP $ 'UP '


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


5FNQFSBUVSF$UP $ 'UP '

0QUJPO$UP $ 'UP '

0QUJPO$UP $ 'UP '

0QUJPO$UP $ 'UP '


*&$BOE*&$GPS&YE**$5
5FNQFSBUVSF$UP $ 'UP '


'BDUPSZ.VUVBM&YQMPTJPOQSPPGUP/&$"SUJDMF
5FNQFSBUVSF$UP $ 'UP '

0QUJPO$UP $ 'UP '

"MUFSOBUJWFGPS(SPVQ#IB[BSEPVTBSFB5FNQFSBUVSFTBTGPS
(SPVQT$BOE%

Canada hazardous Area


$4"&1$MBTT* %JWJTJPO (SPVQT$BOE%IB[BSEPVTBSFBT
$BOBEJBO4UBOEBSE"TTPDJBUJPO&YQMPTJPOQSPPG
5FNQFSBUVSF$UP $'UP '

0QUJPO$UP $ 'UP '

"MUFSOBUJWFGPS(SPVQ#IB[BSEPVTBSFB
Temperature $UP $ 'UP '

0QUJPO$UP $ 'UP '


88

International Non hazardous


WT: Standard watertight, BS EN 60529 :1992,
IP68, 7 metres/72 hours.
5FNQFSBUVSF$UP $ 'UP '

0QUJPO$UP $ 'UP '

0QUJPO$UP $ 'UP '


US Non hazardous
NEMA 4, 4X and 6.
5FNQFSBUVSF$UP $ 'UP '

0QUJPO$UP $ 'UP '

0QUJPO$UP $ 'UP '


Canada Non hazardous


CSA WT: Canadian Standard Association
Watertight.
Wiring and components complying with CSA
Enclosure 4 and 4X.
5FNQFSBUVSF$UP $ 'UP '

0QUJPO$UP $ 'UP '

0QUJPO$UP $ 'UP '


Rotork can supply actuators to national


standards not listed above. For details please
contact Rotork.

AA

81

Heading Fuses
Approved

'4#VTTNBO5%$ SBUJOHBTQFSUSBOTGPSNFSUZQF
4FFBDUVBUPSXJSJOHEJBHSBNGPSUSBOTGPSNFSUZQF

5ZQFN"BOUJTVSHF
5ZQFN"BOUJTVSHF
5ZQFN"BOUJTVSHF
'4 "5&9VOJUTPOMZ

#VTTNBO5%4N"2VJDLCMPXPS-JUUFM'VTFN"2VJDLCMPX

82

Appendix A

EL

Partial Stroke Limit

EP

5IFFOEPGUSBWFMMJNJUGSPNXIJDIUIF
QBSUJBMTUSPLFUFTUXJMMTUBSUBOEFOE
NVTUCFTFU

"QPTJUJPODBOCFTFUCFUXFFO
BOEUPHJWFBTFUQPJOUXJUIJOUIF
USBWFMUPXIJDIUIFQBSUJBMTUSPLFSVOT

The default limit for partial stroke is


0QFOMJNJU VOEFSUFTUUIFBDUVBUPSXJMM
BVUPNBUJDBMMZNPWFDMPTFEGSPNUIF
open limit to the set position and then
SFUVSOUPUIFPQFOMJNJUQPTJUJPO

5PTFUUIFQBSUJBMTUSPLFQPTJUJPO 1SFTT
the + or -LFZUPTDSPMMCFUXFFO
BOE"NJOJNVN4USPLFJT
SFRVJSFEGSPNPQFOMJNJUUPBMMPXUIF
actuator to perform the partial stroke
BEFRVBUFMZ

To set the closed limit for partial stroke


[EL] 1SFTTUIF+ or -LFZUPDIBOHF
from Open [EL OP] to Closed [EL CL]

PRESS THE

Et

Partial Stroke Position

PRESS THE

KEY.

KEY.

Partial Stroke Timeout

5IFUJNFPVUGVODUJPOBMMPXTB
reasonable amount of time to be set
for the partial stroke to complete one
DZDMF"OBMBSNDBOCFTFUUPBDUJWBUFJG
the stroke hasnt been completed in the
TFUUJNF3FGFSUP4FDUJPO JOEJDBUJPO
DPOUBDUT
5IF1BSUJBM4USPLFUJNFPVU
NVTUCFTFUUPBWBMVFHSFBUFSUIBOUIBU
SFRVJSFEUPDPNQMFUFUIF1BSUJBM4USPLF
VOEFSOPSNBMPQFSBUJOHDPOEJUJPOT
5PTFUUIFQBSUJBMTUSPLFUJNFPVU QSFTT
the + or -LFZUPTDSPMMVQPSEPXOJO
TFDPOEJOUFSWBMT
4FUUIFSFRVJSFEUJNFBOEPRESS THE

KEY.

Partial Stroke
Pos: 75%
Partial Stroke
Limit: Open

5IFEJTQMBZPQUJPOXJMMGMBTI[Stored]
JOEJDBUJOHJUIBTCFFOTFU

5IFEJTQMBZPQUJPOXJMMGMBTI[Stored]
JOEJDBUJOHJUIBTCFFOTFU
P.Stroke Timeout
300 seconds

5IFEJTQMBZPQUJPOXJMMGMBTI[Stored]
JOEJDBUJOHJUIBTCFFOTFU

89

83

Rotork Sales and Service


*GZPVS3PUPSLBDUVBUPSIBTCFFO
DPSSFDUMZJOTUBMMFEBOETFBMFE JUXJMMHJWF
ZFBSTPGUSPVCMFGSFFTFSWJDF
4IPVMEZPVSFRVJSFUFDIOJDBMBTTJTUBODF
PSTQBSFT 3PUPSLHVBSBOUFFTUIFCFTU
TFSWJDFJOUIFXPSME$POUBDUZPVSMPDBM
3PUPSLSFQSFTFOUBUJWFPSUIFGBDUPSZ
EJSFDUBUUIFBEESFTTPOUIFOBNFQMBUF 
RVPUJOHUIFBDUVBUPSUZQFBOETFSJBM
OVNCFS
"GVMMMJTUJOHPGPVSXPSMEXJEFTBMFT
BOETFSWJDFOFUXPSLJTBWBJMBCMFPOPVS
XFCTJUFBUwww.rotork.com

Head Office
Rotork Controls Limited
Brassmill Lane
Bath
BA1 3JQ

Local representative:

tel
+44 (0)1225 733200
fax
+44 (0)1225 333467
email mail@rotork.com

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 SOLO
TEMPORANEI. PER UNA PROTEZIONE PERMANENTE PREGO SOSTITUIRLI CON
APPOSITI TAPPI METALLICI.
ATENCION: LOS TAPONES ROJOS DE PLASTICO EN LAS ENTRADAS DE CABLE
SON UNICAMENTE PARA TRANSPORTE. PARA PROTECCION PERMANENTE
COLOCAR TAPONES METALICOS APROPIADOS.
ACHTUNG: DIE ROTEN PLASTIKSTOPFEN SIND NUR FR DEN TRANSPORT
GEEIGNET. FR DAVERHAFTEN SCHUTZ SIND DIESE GEGEN GEEIGNETE
BLINDSTOPFEN AUSZTAUSCHEN.
ATTENTION: LES BOUCHONS PLASTIQUES ASSURENT UNE PROTECTION
TEMPORAIRE. POUR UNE PROTECTION DEFINITIVE UTILISER DES BOUCHONS
METALLIQUES.

As we are continually developing our products,


the design of Rotork actuators is subject to
change without notice. The latest product and
technical information is available at our
website: www.rotork.com.
The name Rotork is a registered trade mark.
Rotork recognises all registered trade marks.
POWTG0409

90

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

Heading

Established leaders in Actuation Technology

IQ

&

IQT Range

electric valve actuators


with intelligent technology

Publication E110E issue 05/04

91

Rotork Actuation

World leaders in valve control

Contents

In the 45 years since the company was founded, Rotork


Actuation has become a byword for excellence in the field
of valve, sluice gate and damper actuation products for
the oil, gas, power, water and waste treatment industries
- worldwide.

Features of the IQ range

Reliability

Intelligent actuation

Protection

Applications

Intelligent communication

We owe our success to an uncompromising focus on


quality at every stage - and at every level - of Rotorks
operations.
From initial site survey, specification and design, through
to materials, manufacturing and testing, installation,
commissioning and after-sales service we accept nothing
but the best.
At the heart of the company is an exceptional workforce the highly trained, forward-thinking engineers, technicians
and support staff who each have a crucial role to play in
maintaining Rotorks unrivalled reputation for innovation,
reliability and first class customer support.

Rotork Pakscan system control

10

Fieldbus system control

11

Construction

12

Second stage gearboxes

14

Actuator specification

15

Performance summary

16

Rotork. Established leaders in actuation technology.

Rotork Controls Ltd, Bath, UK

Rotork Controls Inc, Rochester, USA

92

Rotorks IQ intelligent valve actuator range the best just got better
Rotorks tried and tested range
of IQ intelligent electric valve
actuators is now further enhanced
- retaining legendary features such
as Rotorks unique double sealing
system and non-intrusive infrared
commissioning capability by the
addition of the IQT dedicated
quarter-turn actuator.

sealing with a watertight enclosure


coupled with infra-red set-up and
comprehensive protection systems
have come together to make IQ the
world leader in reliable valve
operation. Gain peace of mind and
minimise maintenance costs with fit
and forget IQ technology.
Simple commissioning

The IQT (IQ quarter-turn) is the result


of ongoing commitment to product
development at the leading edge of
new technology. The Rotork IQ now
delivers a complete range of actuators
suitable for most quarter and
multi-turn applications that require
control and indication flexibility,
offering end users ever higher
standards of performance build quality
and overall value.

Simple, safe and rapid non-intrusive


commissioning with infra-red control.
Actuator settings such as torque
levels, position limits, control and
indication functions can be accessed
and adjusted using the point and
shoot 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.

The IQ continues to offer all the key


benefits which have made it a world
leader including:

Simple troubleshooting

Fit for Life


Whatever the environment, whatever
the duty IQ has become a byword for
reliability. Design simplicity, double

Active valve, control and actuator


alarm icons are provided on the easy
to read illuminated display.
Access comprehensive, real-time,
diagnostic help screens with the IQ
Setting Tool for a full picture of local

and remote control status, actuator


configuration and torque against
position profiles. The on-board data
logger records operational, alarm and
valve torque profile data providing
valuable information of plant operating
performance 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 on


a chip technology

Comprehensive control and


indication flexibility

93

IQ - simply unmatched for reliability

Position measurement
Reliable process control depends on
accurate positioning of the valve at
end of travel and for fluid control, mid
travel. The patented IQ non-contacting
position measuring system is the most
simple yet devised for actuator control.
With only one moving part, the
resolver converts output centre column
rotation into an electronic signal which
is then compared to position limits
stored within a safe, non volatile
memory.
IQT speed control
By use of motor control technology
proven in the AQ range over 20 years
and now integrated with the IQ
actuator on a chip the output speed
of the IQT can be adjusted without
affecting the torque output.

Protection - the key

Non-intrusive - sealed for life

Vast experience in the application of


electric actuators has enabled Rotork
to lead the world in actuator ingress
protection. Situated in environments
ranging from desert to tundra,
offshore to underground, where
flooding, humidity, extremes of heat
and cold, ultra violet and corrosive
atmospheres are normal, actuators
have to perform unfailingly. Rotork
understand that the most important
factor in the reliability of an actuator is
protection from the environment - in
simple terms, the enclosure.

IQ covers need not be removed for site


commissioning. 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 manufacturing
facilities, air exchanges are eliminated all internal components are completely
protected for life. Non-intrusive
control selectors mean there are no
moving shafts penetrating the control
enclosure.
Reliability through simplicity

Double sealed for double


protection
The IQ enclosure is rated IP68 7 metres for 72 hours, NEMA 4/4X/6. It
is completely watertight and dusttight
and does not breathe. The Rotork
Double Seal system ensures protection
of internal components since they are
separated from the cable gland and
terminal compartment by a watertight
terminal block. Protection is maintained
during site hook-up when terminal
covers are removed and is independent
of cable gland sealing.

The IQ combines simplicity of design


while extending specification and
performance.
Torque measurement
An actuators ability to reliably and
accurately determine the force applied
in operating a valve is fundamental
in providing valve and actuator
protection. The IQ range uses tried
and tested technology, proven in
industry. Accurate, repeatable torque
measurement is achieved independent
of variations in frequency, voltage
and temperature.

94

IQ - big on intelligence

Actuator display
The IQ incorporates a unique liquid
crystal display developed specifically
for actuator indication. Large
segments allow easy, distance viewing
of valve position, torque and
diagnostic screens. A unique, diffused
LED backlighting system provides high
visibility in all light conditions. The LCD
display is supplemented with position
indication lights, green, yellow and red.

Looking at an example of a close valve


command, by applying a signal to the
remote close input and close interlock
input simultaneously the actuator will
operate and close the valve. If only
one signal is applied, or a signal is lost,
the actuator will failsafe by staying
put or stopping. When conditional
remote control is configured, the
interlock inputs are not required for
local operation.

Indication back up

Data logging

Rotork recognise the need for local


and remote position indication at all
times, even when the actuator is
powered down. The IQ incorporates
a battery to maintain and update
position indication when the main
power is switched off. The battery
also supports power off data logging
and commissioning.

Every IQ includes an on board data


logger. The data logger captures and
stores 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

Set-up
Infra-red set up, adjustment and
review using the supplied, intrinsically
safe IQ Setting Tool allows users access
to the configuration of the actuator
using the convenient actuator liquid
crystal display.
On screen diagnostic icons
Four dedicated alarm icons are
incorporated into the LCD display
giving clear indication of valve, control
system and actuator alarms.

The data logger is accessed via the


IrDA interface to compatible devices,
see below. Data logger data can be
analysed with IQ-Insight PC based
software, described in detail on page 8.

Help screens

IrDA communication (IQ-Insight)

Nine help screens can be accessed


with the IQ setting tool allowing real
time, grouped analysis of control
signal status, valve and actuator status
and indication status.

IQ supports IrDA compatible


communication. IQ configuration and
data logger files are accessed via the
infra-red port non-intrusively. Data
exchanges are via IrDA with
compatible Personal Digital Assistants
(PDAs), note books or PCs. IQ-Insight
PC software provides the interface
with the actuator and its on-board
data logger.

Valve torque indication

Valve closed

Torque and
position display

Log data is time and date stamped


and can be analysed by playing back
in real time or on an event by
event basis.

Real time viewing of valve torque


against valve position can be accessed
with the Setting Tool via the IQ LCD.
Analysis of valve operating conditions
is therefore available as standard.
Conditional control

Close torque
set to 40%

Diagnostics
display

For applications where a high level of


safety integrity is required the IQ can
be configured for conditional control.
In this mode, operation is conditional
on two discrete signals being applied.

95

Full security, full protection

Syncrophase prevents valve


damage through incorrect wiring
Rotorks unique Syncrophase
automatic phase rotation correction
prevents valve damage through
incorrect wiring by ensuring that the
IQ 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 constantly
monitor all three phases of the power
supply. Should one or more phases be
lost the control circuit is prevented
from energising the contactors. Local
and remote alarm signals of
incomplete supply are offered as
standard features.
Motor protection when valve jams
Should a valve jam, the IQ motor is
prevented from overheating by a logic
circuit which trips the contactor when
there is no movement within seven
seconds of a start signal.
IQT uses a 24 volt DC motor. For
single and 3 phase* supplied actuators
the motor supply is internally provided
via a transformer - rectifier (24 volt DC
supplies - rectifier only). IQT will
always run in the correct direction
irrespective of supply type and
connection. On loss of one or more of
the utilised phases (or DC supply pole)
the IQT actuator will stop.

IQ thermostatic protection
Two thermostats embedded in the
motor windings directly sense
temperature, tripping the actuator
control circuit in the event of
overheating.
IQT thermostatic protection
Two thermostats are embedded in the
toroid transformer windings providing
comprehensive motor power module
protection.
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 presented
using the display icons. At the same
time, actuator operation can be
inhibited to enable site investigation.
Instant reversal protection
An automatic time-delay circuit avoids
the shock loads which may cause
unnecessary wear to valve stems and
gearboxes when an actuator is ordered
to reverse direction instantaneously.
The circuit also limits current surges
through the contactor.

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


** IQ 3 phase only.

96

Customised features

Even though Rotorks standard


IQ actuator offers wide ranging
control and indication flexibility, a
variety of customised features can
be specified to reflect individual
customer requirements. Gearboxes
for multi-turn and part-turn valves
Large or slow moving gate and
globe valves can be motorised
through thrust taking bevel or
spur gear operators on which the
electric actuator is mounted. IQT
provides direct operation of small
to medium sized quarter-turn
valves up to 2000Nm. IQ actuators
can also be fitted with part-turn
worm and wheel gearboxes to
provide increased torque at
reduced speeds for the operation
of part-turn valves. A sizing
program for both part-turn and
multi-turn applications is
available on CD ROM.
IQTF (full turn) actuators
For non-thrust, multi-turn, slow speed
applications, the IQTF provides a
reliable solution with the same general
specification as the IQT range.
For further details please contact
Rotork.
Fireproofing and extreme cold

Floor mounting for easy remote


coupling
Floor stands with upward or
downward stubshafts are available for
coupling, via customer shafts and
universal joints, to remote valves.
Linear output drive assemblies
For applications requiring an actuator
with a linear output, a leadscrew
arrangement can be fitted to the base
of the standard IQ actuator.
Damper actuators
Single blade and multi vane dampers
can be motorised either by direct
connection to the damper spindle or
by lever arm.
Valve stem expansion
The stems of positive seating valves,
such as solid or flexible wedge gates
may be subject to significant
expansion when used in high service
temperature applications resulting in
damaged or leaking valves. The effects
of this expansion or contraction may
be overcome by fitting the Rotork
temperature compensator to the
output of the IQ actuator.
For further details see publication
E152E.

Fully operational at temperatures of


up to +70C, the standard IQ range
actuator can be made operable for
up to thirty minutes in a fire (when
temperatures may quickly climb to
over 1000C) through the use of
boxes, blankets or intumescent
coating, as specified by the customer.
Modifications can also be implemented
to allow cold temperature operation
as low as -50C.
For further details see publication
S310E.

97

Intelligent communication - lifetime support

Lifetime support

PC tools - IQ-Insight - Pocket-Insight

Rotork understands its customers


need for back up. The costs and
penalties of plant downtime, delayed
commissioning schedules and
inappropriate maintenance are too
high to allow for inefficient support.
With IQ - IrDA (Infra-red Data
Association) communication and the
onboard datalogger, the IQ now offers
unrivalled support to provide complete
product back up with analysis and
configuration. With Rotorks unrivalled
worldwide service network expert
advice is always close to hand.

IQ-Insight PC software is a graphical


user interface allowing all IQ set-up
configuration and data logger
information to be reviewed analysed
and reconfigured. The visually
interactive application is browser
based, running under Microsoft or
other internet browser systems.
Familiar tools such as linking,
bookmarking, back and forward
controls, make analysing the data
from an IQ simple and fast. Laptop
PCs with IrDA interface (or serial
port with IrDA interface) running
IQ-Insight can be directly connected
to an actuator located in the field to
allow set-up, adjustment and analysis.

Remote diagnosis - IrDA

The IQ utilises IrDA communication


for fast, safe, non-intrusive and
standardised data exchange. Actuator
set-up configuration can be analysed
and if required changed. As every IQ
includes an on board data logger,
operational data such as valve torque
profiles, actuator events and statistics
can be downloaded for detailed
investigation. Data logger information
can also be relayed to a user site base
via an IrDA compatible PDA. After
analysis, any changes to the actuator
set-up configuration can be relayed
back to the actuator.

Alternatively, using a PDA running IQ


Pocket-Insight, data can be uploaded
from the actuator and later
downloaded to a PC.

Above:
Actuator torque display
using IQ-Insight software

98

Rotork help - online around


the world
Rotork has a comprehensive service
network worldwide to provide you
with in-country support. Rotork
trained technicians working from our
network of offices and centres of
excellence are available to offer
immediate assistance.
To contact Rotork, visit the
website at www. rotork.com

99

Rotork Pakscan system control

Rotork Pakscan IIE Master Station


Available in single or hot standby
configurations the Pakscan IIE master
station can control 240 field devices
over a loop distance of up to 20km without the need for signal repeaters.
The Pakscan IIE is mounted in a
133mm high 19 rack and each
master station comes complete with
dual host communication ports (RS232
and RS485), a user interface LCD
screen and operator keypad. The rack
can house a single unit, two single
units operating independently or a Hot
Standby system. The Hot Standby
version of the IIE features two identical
modules and transfer between the
main and standby is transparent
and automatic in the event of a
component failure.
For further details see publication
S110E.
Rotork Pakscan the total control solution
Whether you need remote control of
just a small number of motorised
valves or full automation of a plant
with thousands of instruments and
control elements, Pakscan can help
you to achieve significant savings in
terms of both time and money.
Thats because Pakscan is capable of
controlling and monitoring up to 240
field devices using a simple shielded,
twisted pair cable loop instead of a
multi conductor cable for each field
device. The system can also gather
important digital and analogue plant
data when its master station(s) are
linked to the double sealed field unit
which is fully integral to each Rotork
actuator.
Together with Pakscans ability to
communicate directly with a PLC or
DCS system via an RS485 or RS232
link, its overall simplicity keeps
customers design work to a
minimum.
For further details see publication
S000E.

In-Vision - powerful, user-friendly


In-Vision is a SCADA (Supervisory
Control And Data Acquisition)
software application for full, user
friendly control of complex
installations such as oil storage depots
and water treatment plants where
there can be a high number of
actuators and process signals to
control and display.

Rotork Pakscan IIS Sequencer


Master Station

Working with Pakscan and running on


a standard PC, In-Vision offers a highly
flexible series of graphic displays and
controls that allow the plant managers
to view and control all aspects of their
process at a fraction of the cost of
other comparable systems.

The Pakscan IIS master station


encompasses the proven features of
the Pakscan 2 wire control system
with the logic and programmability
more commonly found in a PLC to
provide a fully featured sequence and
interlock control package. Easily
programmed by fill in the box menus
the Pakscan IIS can quickly be made
ready to run your plant. Located in the
field close to the process, Pakscan IIS
permits control and monitoring of up
to 32 field units.

For further details see publication


S210E.

For further details see publication


S112E.

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

10

100

Fieldbus system control

R O T O R K PA K S C A N
Central control of up to
240 units on a single loop

DCS
Master Station

Rotork actuator control solutions also


interface to a wide range of
communication and control systems,
including those covered by the major
international 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 fieldbus
protocols such as Profibus, Foundation
Fieldbus, DeviceNet and Modbus are
all available within the IQ actuator
control option range.

2 wire (single pair) fault tolerant and redundant system

FIELDBUS
DCS
Interface

Choose from: Profibus,


Modbus, Foundation
Fieldbus, DeviceNet

This is achieved simply and cost


effectively through fitting an
appropriate Rotork manufactured
circuit board module inside the
actuators electrical housing - normally
at the time of production. Module
commissioning and setup is carried
out using a combination of the IQ
Setting Tool and the network
commissioning tools used for the
chosen protocol.

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

Rotork IQ and IQT actuators are fully compatible with


the following fieldbus communication systems:

Modbus
11

101

Advanced engineering

1 Hand operation
Direct drive handwheel (or geared
handwheel on larger sizes and IQT)
to provide reliable emergency manual
operation in the event of a power
supply failure. With padlockable*
hand/auto clutch for safe operation
even when the motor is running.

IQ

Note: power operation always has


preference unless hand/auto lever is
purposely locked into hand drive.
Lost motion hammerblow effect is
provided with both direct and
independently geared handwheels.

IQT
5
2 Non intrusive setting
All actuator settings and diagnostics
are made through the sealed
indication window. It is not necessary
to remove electrical covers exposing
the integral controls on site.

2
3 Local controls
Local controls and padlockable*
Local/Stop/Remote selector switch
operate internal reed switches,
avoiding penetrating shafts which
would have to be sealed to prevent
moisture ingress.

3
4 Position control
Hall effect magnetic pulse system
accurately measures and controls the
stroke of the actuator without using
gears and switches.

IQ

IQT
12

102

5 Terminal compartment
Separately sealed terminal
compartment ensures the integrity of
the electrical equipment even when
the terminal cover is removed during
site wiring.

1
5
IQ

4
6
2

IQT
3

6 IQ motor and drive


Motor shaft and worm shaft separate
to facilitate simple actuator speed
change. Low inertia high torque
motor. The motor produces peak
torque rapidly after starting but with
very little overrun when de-energized.
The winding thermostat provides
accurate temperature sensing
independent of ambient temperature
conditions to optimize the motors
thermal capacity. The motor drive
includes a lost motion hammerblow
to assist in unseating tightly shut
valves. Single worm and wheel drive
running in an oil bath for maximum
life with ambient temperature
tolerance.
IQT motor
High efficiency compact unit with a
proven reliability record in valve
actuation applications over 20 years.
Integrated speed control allows
output speed adjustment over a 4:1
speed range.

4
7 Thrust base
Cast iron, water sealed bearings.
Easily removable drive bushing for
machining to suit valve stem for
convenient valve adaptation.

6
*Suitable for 6mm / 1/4 inch padlock

7
13

103

Gearboxes

Multi-turn output - IB and IS Range


For multi turn applications the Bevel
(IB) and spur (IS) gear combinations
are available, where screwed or keyed
stems are used to operate the valve.
IQ - IB combinations are available up
to 8,135Nm torque and 1,557kN
thrust output. IQ - IS combinations are
available up to 43,386 Nm torque and
3,342kN thrust output.
Key features:

Totally enclosed, fully sealed and


grease filled for life

Removable output drive coupling


for machining

Comprehensive gear ratios combined


with 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 IQT
provides direct quarter-turn output.
For part-turn applications that require
torques in excess of 2000Nm or where
increased thrust/torque at reduced
operating speed is required, Rotork
produce a range of gearboxes. With
the IW range of gearboxes torque
outputs up to 137,000Nm are
available.

Modulating and submersible gearbox


forms are available. As standard,
gearboxes are despatched painted the
same colour as the actuator.

Key features:

Totally enclosed, fully sealed and


greased filled for life
Removable output drive coupling for
machining, 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

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
Thrust: kN Lbs

3,000 2,200
44 10,000

8,135 6,000
350 1,557

43,386 32,000
3,342 750,000

Actuator type:

IQ

IQ + IB

IQ + IS

14

104

Bevel Gearbox

Spur Gearbox

The following pages contain details


on performance and specification for
the Rotork IQ range of actuators.
Please use the contents table below
to help access the information you
require.

Actuator specification - contents

Performance summaries

p16

Actuator Drive Couplings

p20

Introduction

p23

Mechanical

p23

4.1 Enclosure

p23

4.2 Valve/actuator interface

p24

4.3 Handwheel

p24

4.4 Lubricant

p25

4.5 Finish

p25

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

p29

Actuator Components

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

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

15

105

IQ 3 phase performance summary

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
IQ10

IQ12

IQ18

IQ20

IQ25

IQ35

IQ40

IQ70

IQ90

Torque** Nm

Ft lbf

34

34

34

34

34

34

25

25

25

25

25

25

81

81

81

68

48

41

60

60

60

50

35

30

108

108

80

80

203

203

203

203

176

142

102*

150

150

150

150

130

105

75*

400

400

298

244

244

230

149*

295

295

220

180

180

170

110*

610

610

542

474

474

366

257*

450

450

400

350

350

270

190*

1020

1020

845

680

680

542

406*

750

750

625

500

500

400

300*

1490

1490

1290

1020

1020

745

645*

542*

1100

1100

950

750

750

550

475*

400*

2030

2030

1700

1355

1355

1020

865*

730*

1500

1500

1250

1000

1000

750

640*

540*

1355*

1355*

1000*

1000*

IQ91

IQ95

3000
2200

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

16

** 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.

106

IQ single phase and IQ DC

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

Actuator size

Torque** Nm

IQS12

IQS20

IQS35*

Ft lbf

65

60

45

40

30

25

48

44

33

30

22

18

165

130

130

125

100

80

60

122

96

96

92

74

59

44

450

400

350

320

230

190

135

332

295

258

236

170

140

100

IQ DC - performance data
Actuator output speeds
rpm

Actuator size

18

Torque** Nm

IQD10

IQD12

24

36

48

Ft lbf

34

34

31

27

25

25

23

20

68

68

61

54

50

50

45

40

IQD18

108
80

IQD20

IQD25

163

163

136

108

120

120

100

80

305

305

257

203

225

225

190

150

DC supply voltage
IQD10
IQD12
IQD18
IQD20
IQD25

24V

48V

110V

* 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.

107

17

IQ performance summary

Mechanical data
Actuator size IQ IQS IQD W

10

20

12

25

35

40

70

90

91

95

18
Flange size

Approximate weight**

ISO 5210

F10

F14

F16

F25

F25

F30*

F25

F30

MSS SP - 102

FA10

FA14

FA16

FA25

FA25

FA30*

FA25

FA30

kg

27

46

69

190

190

200

200

200

lbs

60

101

152

418

418

440

440

440

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

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

mm

26

32

45

51

57

57

N/A

N/A

ins

1 /4

1 /4

2 /4

2 /4

N/A

N/A

mm

N/A

51

67

N/A

N/A

N/A

N/A

N/A

ins

N/A

25/8

N/A

N/A

N/A

N/A

N/A

Group A couplings (thrust)


Thrust rating

Stem acceptance diameter


Type A (maximum)
Rising

Non-rising

Type Z - Z3
Z Rising

Z3 Rising

Non-rising

mm

32

51

67

73

83

83

N/A

83

ins

11/4

25/8

27/8

31/4

31/4

N/A

31/4

mm

N/A

38

51

57

73

73

N/A

73

ins

N/A

1/

2/

2/

2/

N/A

27/8

Group B couplings (non-thrust)


Bore diameter
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

/4

11/4

13/4

21/4

21/4

21/4

N/A

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

30:1

45:1

30:1

45:1

Handwheel ratio

18

* 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.

108

IQT quarter-turn performance summary

Performance and mechanical data


Actuator

IQT125

IQT250

IQT500

IQT1000

IQT2000

Max Nm
Min Nm

125
50

250
100

500
200

1000
400

2000
800

Max Ft lbs
Min Ft lbs

92
37

185
74

369
148

738
295

1476
590

5
20

8
30

15
60

30
120

60
120

Torque

Operating time
90 Min
90 Max
Flange
ISO 5211
MSS SP-101

F05* F07* F10


FA05* FA07* FA10

F07*
FA07*

F10
FA10

F10
FA10

F12
FA12

F14*
FA14*

F14
FA14

Weight
Kg
lbs

22
49

22
49

22
49

37
82

37
82

Couplings**
Spindle acceptance

Bore & key max mm


Bore & key max ins
Square AF max mm
Square AF max ins

22
0.87

28
1.1

42
1.65

28
1.1

42
1.65

42
1.65

60
2.36

60
2.36

14
0.56

19
32
0.75 1.25

19
0.75

32
1.25

32
1.25

41
1.62

41
1.62

Handwheel
Turns for 90

80

80

80

80

80

80 - 100

80 - 100

80 - 100

80 - 100

80 - 100

Angular
adjustment
(nominal) degrees

IQT 24V DC (17-37 Volts) Performance


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

* Optional flanges F05, FA05, F07 and FA07 use a base adapter plate. Required base type must be specified.
19

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

109

IQ actuator drive couplings

2 Actuator drive
couplings

Actuators IQ10 IQ12 IQ18 IQ20 IQ25 IQ35


T h r u s t

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, 91
and 95. Both arrangements are
available with flanges and
couplings which comply with
either ISO 5210 or MSS SP-102.

Type A

Type Z

Type Z3

for sizes IQ10 to 35

for sizes IQ20 to 35


increased stem
acceptance

for sizes IQ10 to 35


increased stem
acceptance
and reach

Removable thrust base

N o n - T h r u s t

20

Type B1

Type B3

Type B4

for sizes IQ10 to 35


large fixed bore
with ISO standard
bore and keyway

for sizes IQ10 to 35


fixed bore with
ISO standard bore
and keyway

for sizes IQ10 to 35


blank drive bush
for machining
by customer

Removable non-thrust base

110

Thrust bearings

Actuators IQ40 IQ70 IQ90 IQ91 IQ95

Both type A and Z couplings feature


an associated thrust bearing. In the
case of the removable thrust base this
is fully sealed and lubricated for life; in
the integral base design this is
lubricated by the actuator gearcase oil
bath. Both integral and removable
thrust bases are designed to retain all
developed thrust reaction forces
without any load appearing on the
actuator gearcase.

T h r u s t
Position 1

Position 2

Type A

Type Z3

for sizes IQ40, 70


and 90

for sizes IQ40, 70, 90


and 95 increased
stem acceptance
and reach

Standard centre column


with thrust bearing

N o n - T h r u s t

Type B1

Type B3

Type B4

for sizes IQ40, 70


and 90 large fixed
bore with ISO
standard bore
and keyway

for sizes IQ40, 70,


90 and 91 fixed
bore with ISO
standard bore
and keyway

for sizes IQ40, 70,


90 and 91
blank drive bush
for machining
by customer
21

Non-thrust centre column

111

IQT actuator drive couplings

Drive couplings*

Actuators IQT125 IQT250 IQT500

The easily removable drive bush


is supplied blank for machining
to suit valve stem for convenient
valve adaption. The IQT base
design and drive couplings
comply with either ISO 5211 or
MSS SP-101.

F05/FA05

F07/FA07

F10/FA10

for size IQT125

for sizes IQT125/250

for sizes
IQT125/250/500

Actuators IQT1000 IQT2000

22

F12/FA12

F14/FA14

for size IQT1000

for size IQT2000

*bore and key is for illustrative purposes


only. Drive bushes are supplied blank as
standard.

112

Standard specification

4 Mechanical

3 Introduction
IQ actuators are self contained units for local and remote
electrical operation of valves. Comprising an electric motor,
reduction gearing, reversing starter with local controls, turns
and 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 with
each order.
The following specification covers standard features and
available optional features. Options selected must be
specified with enquiry.

4.1 Enclosure and ambient


temperatures
All IQ actuator hazardous and nonhazardous area enclosures are built to
a watertight standard. Through the
use of non-intrusive commissioning
and site adjustment using the
supplied infra-red IQ Setting Tool, the
hermetic, factory-sealed enclosure
protects internal components for life
as covers never need removing. The
terminal compartment is sealed from
other areas by the Rotork double
seal, maintaining watertight integrity
even during site connection.
Actuators are available with the
following enclosure types for which
the ambient working temperature
ranges are stated. Where option
temperatures are indicated, changes
to some actuator components are
required and therefore the
temperature requirement must be
specified. Hazardous area approvals
for other country standards are
available, please apply to Rotork.
The IQ range is built in accordance
with the following standards:

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

WT: Standard watertight,


IEC 60529 (1989-11),
IP68 7 metres/72 hours,
NEMA 4, 4X and 6.
Temperature -30C to +70C
(-22F to +158F).
*Option -40C to +70C
(-40F to +158F).
*Option -50C to +40C
(-58F to +104F).
European - Hazardous Area
EExd IIB T4. ATEX (94/9/EC) II 2GD:
CENELEC Norm EN50014 and
EN50018.
Temperature -20C to +70C
(-4F to +158F).
*Option -30C to +70C
(-22F to +158F).
*Option -40C to +70C
(-40F to +158F).
*Option -50C to +40C
(-58F to +104F).
EExd IIC T4. ATEX (94/9/EC) II 2GD:
CENELEC Norm EN50014 and
EN50018.
Temperature -20C to +70C
(-4F to +158F).

113

23

Standard specification

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


CENELEC Norm EN50014, EN50018
and EN50019.
Temperature -20C to +70C
(-4F to +158F).
Option -30C to +70C
(-22F to +158F).
Option -40C to +70C
(-40F to +158F).
Option -50C to +40C
(-58F to +104F).
EExde IIC T4. ATEX (94/9/EC) II 2GD:
CENELEC Norm EN50014, EN50018
and EN50019.
Temperature -20C to +70C
(-4F to +158F).
International - Hazardous Area
IECE. Exd IIB T4:
IEC60079-0 and IEC60079-1 for Exd
IIB T4.
Temperature -20C to +60C
(-4F to +140F).
IECE. Exd IIC T4:
IEC60079-0 and IEC60079-1 for Exd
IIC T4.
Temperature -20C to 60C
(-4F to +140F).
USA - Hazardous Area
FM. Class 1, Division 1, Groups C,
D, E, F, G hazardous areas:
Factory Mutual - Explosionproof to
NEC Article 500.
Temperature -30C to +60C
(-22F to +140F).
Option -40C to + 60C
(-40F to +40F).
Option -50C to +40C
(-58F to +104F).
Alternative for Group B hazardous
area. Temperatures as for Groups
C and D.
Canada - Hazardous Area

24

CSA EP. Class 1, Division 1, Groups


C and D hazardous areas:
Canadian Standard Association Explosionproof.
Temperature -30C to +70C
(-22F to +158F).
Option -50C to +40C
(-58F to +104F).
Alternative for Group B hazardous
area. Temperatures as for Groups
C and D.

International - Non Hazardous


WT: Standard watertight, BS EN
60529 :1992, IP68, 7 metres/72 hrs.
Temperature -30C to +70C
(-22F to +158F).
Option -40C to +70C
(-40F to +158F).
Option -50C to +40C
(-58F to +104F).
US - Non Hazardous
NEMA 4, 4X and 6:
Temperature -30C to +70C
(-22F to +158F).
Option -40C to +70C
(-40F to +158F).
Option -50C to +40C
(-58F to +104F).
Canada - Non Hazardous
CSA WT: Canadian Standard
Association -Watertight. Wiring
and components complying with
CSA Enclosure 4 and 4X:
Temperature -30C to +70C
(-22F to +158F).
Option -40C to +70C
(-40F to +158F).
Option -50C to +40C
(-58F to +104F).
Rotork can supply actuators to
national standards not listed
above. For details please contact
Rotork.
4.2 Valve/actuator interface
The range of IQ actuators is available
with mounting base and output drive
couplings conforming to international
standard ISO 5210 or USA standard
MSS SP-102. IQT actuators are
available with mounting base and
output drive couplings conforming to
ISO 5211 or US standard MSS
SP-101. Applications for which the
various types of couplings have been
designed are outlined on pages 20-22
4.3 Handwheel
Handwheels are provided to allow
manual operation of the valve during
electrical power interruption.
IQ10 - IQ40 Direct acting top
mounted handwheel. Option: side
mounted geared handwheels.

114

IQ70 - IQ95 Side mounted geared


handwheel. Option: alternative gear
ratios.
IQT all sizes. Side mounted geared
handwheel.
During electric operation of the
actuator the handwheel is
mechanically disengaged from the
drive. To engage handwheel
operation, the hand/auto selection
lever is depressed and released after
which handwheel operation remains
selected. When electrical operation
takes place, the actuator will
automatically return to motor drive
without lever or handwheel kickback.
The hand/auto selection lever
incorporates a facility for locking in
the hand or auto positions using a
6mm diameter hasp padlock (not
supplied by Rotork), preventing
engagement of motor drive (locked in
hand) or engagement of handwheel
drive (locked in auto). Emergency
disengagement of motor drive can be
selected by depressing and holding
the lever during electric operation.

4.4 Lubrication
IQ and IQT actuators are factory filled
for life with premium quality gear oil
specified as SAE 80/90 EP for IQ and
Dextron 2 for IQT. Oil lubrication
out-performs grease over the IQ
temperature range -30C to +70C,
with none of the problems associated
with grease such as separation and
tunneling. Rotork have used this same
grade of lubricating oil for 40 years.
Lubrication options
Food grade lubricant
IQ and IQT actuators may be supplied
with the gearcase filled with Hydra
Lube GB Heavy food grade lubricant.
This lubricant is a synthetic nonaromatic hydrocarbon mixture with
PTFE and other additives. It does not
contain chlorinated solvents. Grease
used in assembly and thrust bearings
is Hydra Lube WIG Medium-NLGI-123.
Extreme temperature service
Where actuator service requires
operation outside of -30C to +70C
alternative lubricants are available,
please apply to Rotork.

4.5 Finish
All IQT and IQ actuators up to size
IQ35 are finished in polyester powder
coating, colour silver grey. Actuators
size IQ40 and above are finished in
air-dried urethane reinforced synthetic
alkyd resin colour, silver grey. For full
specification of paint finish see
publication E151E.
Finish options
Colour: Other colours may be specified, please apply to Rotork.
Offshore: 2 pack epoxy coatings are
available for extreme environmental
conditions, please apply to Rotork.

50Hz
200, 220, 240, 380, 400, 415, 440,
480, 500, 550, 660 and 690 volts
60Hz
200, 208, 220, 230, 240, 380, 400,
440, 460, 480, 575, 590, 600, 660
and 690 volts
The required nominal operating
voltage must be specified at time of
order.
Actuator performance is guaranteed
with a voltage tolerance +/-10% and
frequency tolerance +/-5Hz. Actuators
are capable of starting and running
up to speed with a maximum 15%
volt drop.

Available for the following DC


supplies:
IQD: 24, 48 and 110 volts
IQT: 24 volts
Non-standard voltages
Actuators can be supplied to operate
on power supply voltages other than
those quoted above. Please apply to
Rotork.
Non standard tolerances
Where voltage and/or frequency
variations may be experienced outside
those quoted above, or where
operation under large volt drop
conditions may be required please
apply to Rotork.

Uninterruptable power supplies


Standard actuators can be operated
on UPS systems providing the above
specified tolerances are not exceeded
and waveforms, harmonics, spikes
etc. adhere to recognised supply
standards such as EN50160. For more
information refer to publication
E130E.
Power supply options

5 Electrical

IQS and IQT single phase

5.1 Power supplies

Available for standard single-phase


voltages:
50Hz: 110, 115, 120, 220, 230 and
240 volts
60Hz: 100, 110, 115, 120, 208, 220,
230 and 240 volts

IQ and IQT actuators are suitable for


operation with the following three
phase, three wire power supplies:

IQD and IQT DC

5.2 Control
Local control
Non-intrusive selectors are provided
on the actuator electrical control
cover, one for Local/Stop/Remote
selection, pad-lockable in each
position, and the other for Open/
Close control. Controls may be rotated
to suit actuator orientation.
Local control may be selected to
operate using the supplied IQ Setting
Tool. The Setting Tool incorporates
dedicated open, stop and close
buttons and will operate over a
nominal distance of 0.75 metres from
the display window.
25

115

Standard specification

Local control option


Vandal resistant
Selectors removed, indication window
with removable cover, control of
local, stop and remote selection and
local open and closed control is via
the supplied IQ Setting Tool.
Remote control
There are six control inputs for
remote 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 derived
from a stayput contact. For more
information refer to publication
E120E.
Control inputs are opto-isolated
interfaces with a surge immunity of
2kV. Control is positive switching
negative earth, internally fed from the
actuator 24V DC customer supply or
from external supplies within the
ranges 20-60V AC or DC or 60-120V
AC.
ESD can be configured off, active
high or active low, to close or open
the valve, with or without automatic
motor thermostat bypass*. ESD will
override any local or remote signals
that may be active. If required ESD
can be configured to override local
stop, interlocks or the optional
interrupter timer. The ESD input
operates from a separate common
allowing isolation between the ESD
control system and operational
control systems.
*Bypassing the motor thermostat will invalidate
hazardous area certification.

Remote control can be configured


so that the open signal and open
interlock (or closed signal and closed
interlock) can be combined to form a
remote open (or closed) signal that
can detect single faults. When
configured, interlocks will not be
active during local control. For more
information refer to publication
E120E.
26

Remote control options


Negative switching
For remote control systems where the
negative pole of the remote control
circuit supply is switched.
External control circuit supplies
For control with supplies in the range
60 - 125V DC and 230V AC an
alternative control circuit option is
available.
Analogue Proportional Control
The Rotork Folomatic proportional
controller enables the actuator to
automatically 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 the
whole valve stroke or if required, a
set portion of stroke. By incorporating
a remote manual/remote auto control
selector in the control scheme,
proportional control can be overridden allowing standard remote
control operation to take place when
manual intervention is required (see
above). The Folomatic can be
configured to failsafe stayput, open
or closed on loss of analogue signal.

116

Hydraulic shock/surge protection


IQ
Where the operating time of the
valve must be increased to prevent
hydraulic shock or water hammer,
or to prevent surges, the Rotork
Interrupter Timer option can be
included. Pulsed operation with
independently adjustable on and off
time periods in the range 1-99
seconds can be selected to operate
over any portion of the closing or
opening valve stroke, effectively
reducing valve speed. On/Off time
period range may be extended when
configuration is carried out with the
IQ-Insight PC tool. The interrupter
timer is active for both local and
remote control.
Hydraulic shock/surge protection
IQT
The IQT actuator allows the output
speed to be adjusted with the Setting
Tool. Refer to performance summary,
page 19. Speed control over 4:1 ratio
is available and settable non
intrusively. The IQT also includes the
Interrupter Timer option (as above)
for extended operating times.

5.3 Indication, monitoring and


data logging
Local
A back-lit liquid crystal display gives
digital indication from fully open to
fully closed in 1% increments. Three
LEDs coloured red, green and yellow
for indication of open, close and
intermediate positions respectively are
also provided. The display includes
four icons for rapid diagnosis of valve
alarm, actuator alarm, control system
alarm and actuator battery status.
With the supplied IQ Setting Tool,
actuator torque plus position can be
displayed allowing the valve torque
against position to be monitored in
real time. Help screen diagnosis is
available for monitoring valve,
actuator and control system status.
The local display can be rotated to
suit actuator orientation. LED colours
can be reversed. Please specify with
order.
Remote
Four latching volt free contacts, S1,
S2, S3 and S4 are provided each
independently configurable using the
supplied IQ Setting Tool to signal one
of the following:
Valve Position
fully open, fully closed or intermediate
positions (0-99% open).
Status
Valve opening, closing, moving
(continuous or pulsing signal),
Local stop selected, local selected,
remote selected, open or close
interlock active, ESD active.

Monitor relay

Indication options

An independent relay with a volt-free


changeover contact for monitoring
actuator electrical availability.

Remote analogue position indication:


The Current Position Transmitter (CPT)
provides a contact-less internally fed
4-20mA analogue signal proportional
to valve position, selectable for
minimum signal corresponding to
fully closed or fully open position
with automatic zero and span setting.
An externally powered version of the
CPT is also available.

Contact rating 5mA to 5A, 120V AC,


30V DC. The relay will de-energise
under any of the following
conditions:
Loss of one or more of the power
supply phases.
Loss of control circuit supply.
Local control selected.
Local stop selected.
Motor thermostat tripped.

Remote analogue torque indication


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

Data logger
The on board data logger allows
infra-red, IrDA( (Infra-Red Data
Association) standard, download of
historical actuator/valve performance
data to PC or via an IrDA compatible
PDA.
For hazardous areas the intrinsically
safe Rotork Communicator tool is
available. Rotork IQ-Insight PC
software allows data logger
information of operational events and
statistics all time and date stamped
plus valve torque/position profiles,
both last operation and historical
trends, all to be analyzed. For more
information please refer to
publication E111E.

Extra indication contacts*


The extra indication contacts module
provides an additional four changeover contacts, S5, S6, S7 and S8.
Each contact is latching, volt free and
rated at 5mA to 5A, 120V AC, 30V
DC. The extra indication contact
functions are independently
configurable in the same way as the
standard contacts using the supplied
IQ Setting Tool. The extra indication
contact functions available are shown
below:

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

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 (3 phase IQ only),
customer 24V DC (120V AC) supply
lost, battery low, internal failure
detected, thermostat tripped.
Each contact can be configured to
either normally open or normally
closed and rated at 5mA to 5A,
120V AC, 30V DC.

27

117

Standard specification

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 field
unit for remote control and status
indication over a fault tolerant twowire serial link. Loop distances of up
to 20 km without repeaters and host
communications using Modbus
protocol. System variables
programmable over the infra-red
data link. For more information
please refer to publication SOOOE.
Modbus
Modbus modules suitable for single
or dual communication highways may
be included in the IQ and IQT
actuator to provide fieldbus
communication of all the actuator
control functions and feedback data.
The fieldbus information is carried on
an RS485 data highway and the
communications protocol used is
Modbus RTU. System variables such
as unit address and data baud rate
are programmed over the infra-red
data link. For more information
please refer to Rotork.

Foundation Fieldbus

Jammed valve protection.

An IEC 61158-2 compliant Foundation


interface module allows the actuator
to 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 directly
between themselves without the
need of a host supervisory system.
For more information please refer
to Rotork.

Motor thermostat protection.

DeviceNet
The ODVA certified DeviceNet
interface module, with full status data
feedback and actuator digital and
analogue control, connects directly to
the popular DeviceNet data highway.
Data feedback includes both torque
and high accuracy position information
while the inbuilt positioner allows for
full modulating control. Up to 63 IQ
actuators can be connected on a
single DeviceNet highway. For further
information refer to publication S116E.

5.5 Protection
The IQ control system incorporates
the following valve, actuator and
control protection:
Obstructed valve (torque trip)
protection.
Lost phase protection plus automatic
phase rotation correction by
Syncrophase.

Profibus

28

A Profibus DP interface module is


available to allow the actuator to be
integrated into a Profibus network.
Full compatibility with EN 50170 is
provided and the Profibus network
allows full actuator control and
feedback of data to the host. For
more information please refer to
publication S113E.

118

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


Actuator control circuit supply
protection.
Instantaneous reversal protection.
Control signal fault protection
(configurable).
5.6 Actuator set-up
All actuator settings may be
configured using the supplied IQ
Setting Tool over the infra-red
interface without the removal of any
covers. Setup can take place with
main power on or power off, during
which power is provided by the
actuator battery. Each IQ actuator
includes a comprehensive installation
and maintenance manual providing
information on site commissioning
and adjustment. An actuator wiring
diagram is also included. As an
option Rotork IQ-Insight software for
PC allows configuration of actuator
settings. For Bus control system
options, tools are available allowing
configuration testing over the serial
interface as well as by Setting Tool or
IQ-Insight software for PC.

Standard specification

6 Actuator components
6.1 Motor
IQ 3 phase
Three phase, Class F, insulated squirrel
cage motor of special high torque
low inertia design. 15 minute rated
with cyclic duration factor of 25% at
33% of actuator output rated torque
giving a temperature rise not
exceeding that permitted for Class B
insulation at standard nominal
voltage. Actuator rated up to 60 starts
per hour at a rate not exceeding 600
starts per hour. Burnout protection by
embedded thermostat, with facility
for bypassing under emergency
shutdown control. For details of
motor performance and use of
uninterruptable power supplies please
refer to publication E130E.
Motor options
Modulating
When a higher number of starts per
hour are required (up to 1200 starts
per hour) IQM/IQTM and IQTFM have
been specifically designed for these
duties. For further details please refer
to IQM/IQTM publication E410E.

Option - Control circuit supply


Nominal 110V AC supply, rated at
20VA (not available with IQD).
*Single Phase and IQM modulating units utilise a
solid state motor starter.

IQT
The IQT power module consists of a
torroid power transformer with a fast
acting micro controller based,
intelligent switch mode motor drive.
Customer remote control supply is an
isolated 24V DC rated at 5W or an
optional nominal 110V AC supply
rated at 20VA.
6.3 Control module
IQ and IQT
Incorporating a single integrated
circuit, hard-wired logic control for
the actuator together with infra-red
(IrDA) interface for external nonintrusive settings and interrogation by
IQ-Insight configuration and data
logger viewer PC tool. On board data
logger records operational data, valve
torque/position profiles and statistical
information, all time and date
stamped.

IQS Single Phase

6.4 Torque and position control

Capacitor start/run squirrel cage


induction motor.

IQ
Position and torque are adjustable as
follows:

IQD Direct Current


Permanent magnet, DC motor
incorporating thermostatic protection.
IQT
24V DC permanent magnet, low
inertia motor. The IQT motor has a
proven 20 year record in valve
actuators.
6.2 Power module
IQ
The power module incorporates
a mechanically and electronically
interlocked reversing contactor
starter*. The control supply
transformer, fed from two phases of
the incoming power supply, provides
internal control circuit supplies and an
isolated, nominal 24V DC customer
supply rated at 5W for actuator fed
remote control circuits. The Rotork
Syncrophase circuit incorporates
phase rotation correction and lost
phase protection.

Position setting range:


2.5 to 100,000 turns, with a
maximum angular resolution to 7.5
of actuator output center column.
IQT
Torque setting:
40% to 100% rated torque. Torque
sensing is derived from drive current
sensing and digital filtering.
Position setting range:
Limits are factory set to 90 stop bolt
positions (nominal). Limit setting
range: 10 to 1800. Maximum
angular resolution to 0.1.
The IQT actuator speed range can be
configured with the IQ Setting Tool.
Output torque for the IQ, is
obtained via the direct measurement
of wormshaft thrust reaction under
load and is independent of voltage,
frequency and temperature
fluctuations.

119

For the IQT the output torque is


measured using the motor current.
Torque off during unseating or during
starting/reversing in mid travel against
high inertia loads can be inhibited.
The jammed valve protection circuit
de-energizes the motor if no
movement occurs after a few seconds
from receipt of a signal to open or
close.
When power to the actuator is
isolated, all settings are retained in an
EEPROM. In the event of manual
operation of the valve during isolation
or loss of the power supply a battery
provides power to the internal
position-monitoring transmitter to
update the valve position data in the
EEPROM. The battery also drives the
LCD display, without backlighting,
and the four latching contacts S1-S4
while the power to the actuator is
not available. Based on a typical
application the minimum battery life
is 5 years. Infra-red setting is also
available with main power off.
6.5 Conduit entries, terminals
and wiring
IQ actuators
Three threaded conduit entries are
provided tapped: 1 x 11/2 and 2 x 1
ASA NPT.
Unless otherwise specified, actuator
will be dispatched with adapters: 1 x
M40 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 installer
to ensure the appropriate cable/
conduit adapters and blanking plugs
are fitted, in order to maintain
hazardous area certification and
ingress protection levels. Certified
adapters and blanking plugs are
available as optional extras.
If specified with order, a fourth
conduit entry can be provided tapped
1 ASA NPT with adapter to M25 or
as an alternative PG16.
IQT actuators
Standard cable entries 2 off M25.
Additional 2 off M25 entries available
as option. Adaptors for M20, NPT 1,
11/4, 11/2 option.

29

Standard specification

Separately sealed compartment


containing segregated metric thread
M5 power and M4 control terminals.
Terminal screws and washers are
supplied with the actuator. The
terminal box cover carries a terminal
identification code card. An
Installation and Maintenance manual
(E170E2) and wiring diagram are
enclosed with each actuator.
Jig built harnesses of individually
numbered stranded conductors,
tropical grade PVC insulated, connect
internal components to the sealed
terminal block. All internal control
connections to the printed circuit
boards are via plugs and sockets.

7 Design specification
7.1 Design life
For isolating duty, torque ratings of IQ
actuators are based on a minimum
maintenance free life of 10,000
open/close/open cycles with rated
seating torque at stroke end and an
average of 1/3 rated seating torque
during stroke. For modulating duty
during stroke please refer to IQM
Range, publication E410E.
Life tests
Standard IQ life test is based on
10,000 open/close/open cycles
(500,000 output turns) with
maximum seating torque at stroke
end and an average of 1/3 max.
seating torque during stroke.
Actuators are stalled against a solid
object 25 times to prove durability.
Standard IQT life test is based on
25,000 open/close/open cycles at
75% rated torque rising to 100% at
each end of travel.

7.2 Frequency of operation


IQ actuators are suitable for valve
duty up to 60 starts per hour.
IQM/IQTM Modulating service: up to
1200 starts per hour.
IQ Single Phase: up to 60 starts per
hour.
IQDC: up to 60 starts per hour.
30

7.3 Operating temperature

Machinery directive

Actuators are suitable for operation


for ambient temperatures in the
range -30C to +70C. Please note Hazardous Area certification defines
the temperature operating range to
maintain certification. Refer to 4.1.

Actuators follow the provision of the


Machinery Directive (89/392/EEC) as
amended by 91/368/EEC and
93/44/EEC.

For temperatures outside this range


please apply to Rotork.

7.4 Vibration
Standard IQ and IQT Range actuators
are suitable for applications where
vibration severity does not exceed the
following applied at the actuator
interface:
Plant induced: Where the cumulative
level of all vibration within the
frequency range of 10 to 1000Hz is
less 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 is
only required to maintain structural
integrity.
Where excessive plant induced
vibration is anticipated, mounting the
actuator remote from the valve and
driving via extension shafting
incorporating vibration absorbing
couplings may provide a satisfactory
solution. Contact Rotork for further
details.

7.5 Safety integrity


Electromagnetic compatibility
directive (EMC)
Actuators conform to the requirements of the European Economic
Community EMC Directive
89/336/EEC as amended by
92/31/EEC. Contact Rotork for a copy
of our Declaration of Conformity.
Low voltage directive (LV)
Actuators conform to the
requirements of the European
Economic Community Low Voltage
Directive 73/23/EEC amended by
93/68/EEC by the application of EN
60204-1 1993. Contact Rotork for a
copy of our Declaration of Conformity.

120

The IQ must not be put into service


until the equipment into which it is
being incorporated has been declared
to be in conformity with the provisions of the European Community
Machinery Directive (89/392/EEC)
91/368/EEC and 93/44/EEC. Contact
Rotork for a copy of our Declaration
of Incorporation.

7.6 Noise
Independent tests have shown that at
1m generated noise did not exceed
61db(A).

IQ

IQT

121

UK head office
Rotork Controls Limited
tel: +44 (0)1225 733200
fax: +44 (0) 1225 333467
mail@rotork.co.uk

USA head office


Rotork Controls Inc
tel: +1 585 328 1550
fax: +1 585 328 5848
info@rotork.com

Australia
tel: +61 353 381566
fax: +61 353 381570
mail@rotork.com.au

Germany
tel: +49 2103 95876
fax: +49 2103 54090
info@rotork.de

Italy (Fluid System)


tel: +39 0583 93061
fax: +39 0583 934612
fluid@fluidsystem.it

Russia
tel: +7 (095) 976 3806
fax: +7 (095) 234 9125
rotork.russia@mtu-net.ru

Thailand
tel: +66 2 2727165
fax: +66 2 2727167
mail@rotork.co.th

Canada
tel: +1 403 5699455
fax: +1 403 5699414
info@rotork.ca

Hong Kong
tel: +852 25202390
fax: +852 2 5289746
rotorkhk@netvigator.com

Japan
tel: +81 3 5632 2941
fax: +81 3 5632 2942
mail@rotork.co.jp

Saudi Arabia
tel: +966 3 833 1661
fax: +966 3 833 9369
rotork@concept.net.sa

U.K. (Electrics)
tel: +44 1225 733 200
fax: +44 1225 333 467
mail@rotork.co.uk

China (Shanghai)
tel: +86 21 64785015
fax: +86 21 64785035
crouse.shen@rotork.com.cn

India
tel: +91 44 6254219
fax: +91 44 6257108
rotork@rotork.co.in

Korea (South)
tel: +82 31 2650962
fax: +82 31 2651369
rotork@rotork.co.kr

Singapore
tel: +65 645 71233
fax: +65 645 76011
philip.seah@rotork.com.sg

U.K. (Fluid System)


tel: +44 113 2057 200
fax: +44 113 2363 310

China (Beijing)
tel: +86 10 8284 5700
fax: +86 10 8284 5697
rotorkbj@public3.bta.net.cn

Indonesia
tel: +62 21 580 6764
fax: +62 21 581 2757
rotork@indosat.net.id

Malaysia
tel: +60 3 5192 8816
fax: +60 3 5192 8821
rotork@rotork.com.my

South Africa
tel: +27 11 4539741
fax: +27 11 4539894
howard.mutters@rotork.co.za

USA
tel: +1 585 3281550
fax: +1 585 328 5848
info@rotork.com

France
tel: +33 1 43 111550
fax: +33 1 48 354254
mail@rotork.fr

Italy (Electrics)
tel: +39 0245 703300
fax: +39 0245 703301
rotork.italia@rotork.it

Netherlands
tel: +31 10 4146911
fax: +31 10 4144750
sales@rotork.nl

Spain
tel: +34 94 6766011
fax: +34 94 6766018
rotork@rotork.es

Venezuela
tel: +58 212 953 9473
fax: +58 212 953 6886
rotorkvz@cantv.net

A full listing of our worldwide


sales and service network is
available on our website at
www.rotork.com

Rotork Controls Inc, Rochester, USA


Rotork Controls Ltd, Bath, UK

sales@fluidsystem.co.uk

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.

122

IW Series AWWA
C504 Quarter-turn Worm Gear Operator

IW Quarter-turn Worm
Gear Operator

Features

Options

100% grease filled for life


and fully sealed

Stem extensions

The IW AWWA C504 worm gear operators are suitable


for both motorized and manual actuation of AWWA
C504 butterfly valves. They are designed to meet or
exceed all aspects of AWWA C504 specification and are
manufactured from high quality and reliable materials.
Overload and life tests reports are available upon
request. All Rotork Gears actuators are made to ISO
9001 standards.

Comprehensive gear ratios


combined with a

selection of input gear
reducers

Angular contact bearings


supporting the worm shaft
Removable and
repositionable drive sleeve
-40 to 250 F standard
temperature range
Adjustable travel stops
+/- 5 degrees
Maximum rated
output torque -
1.47 million in-lbs
Maximum stem acceptance
diameter - 12 bored with
ANSI B17.1 square key
Maximum base - FA40
Above or Buried Service

Established Leaders in Actuation Technology

123

Padlock kit
NAMUR & Westlock Position
indicator mounting kit
High temperature:
0 to 300 F
Low temperature
down to -60 F
Open Right Service
450 ft-lbs Service

IW Series AWWA
C504 Quarter-turn Worm Gear Operator

Material Specification

Component

Material

Specification / Notes

Ductile Iron
Cast Iron
Steel
Manganese Bronze
Steel
Steel
Angular Contact
Nitrile
316 SS
Renolit CL-X2
431 SS

ASTM A536 65-45-12


ASTM A48 35B/40B
AISI 4340
ASTM B584 C86300
AISI 1023
AISI 1023 or 1040 or 1055

Gearcase
Base plate
Worm Shaft
Quadrant
Position Indicator
Drive sleeve
Bearings
O-Ring seals
Fasteners
Grease
Input Shaft

Handwheel Selection Chart


H

F Type handwheel

RIM Effort in lb

40

40

60

80

120

36
32

N SPOKES

28

Type

8
12
16
20
24
28
32
36
40
44
48

F200
F300
F400
F500
F600
F700
F800
F900
F1000
F1100
F1200

K
2.97
3.96
3.96
3.96
3.96
3.96
3.96
3.96
3.96
3.96
3.96

3
3
4
4
4
6
6
6
6
6
8

Handwheel Diameter in inches

Dimensions

24
20

Example how to use this Chart:


1 Get the input torque required

16
12
12
8
8

Output Required
M.A.
2 Define Maximum allowable RIM effort
Input Torque =
(standard is 80lb)

3 Select Handwheel diameter


10 20 30 40 50
Input Torque in Ft-lb

60

70

80

90 100 110 120 130 140 150 160 170 180 190 200

Rotork Gears BV
Nijverheidstraat 25
7581 PV Losser
P.O. Box 98
7580 AB Losser
The Netherlands

Rotork Gears UK
Regina House
Ring Road
Bramley, Leeds
West Yorkshire LS13 4ET
England

Rotork Gears Americas


1811 Brittmoore
Houston
Texas 77043
USA

Rotork Gears S.R.L.


via Olona, 65/67
20015 Parabiago (MI)
Italy

Rotork Gears Shanghai


No. 260 Lian Cao Road
Xin Mei Urban Industrial Park
Min Hang District
Shang Hai 201108
China

tel: +31 (0)53-5388677


fax: +31 (0)53-5383939
email: info@rotorkgears.nl

tel: +44 (0)113 2057276


fax: +44 (0)113 2563556
email: sales@rotorkgears.com

tel: +1 713 983 7381


fax: +1 713 856 8022
email: gears@rotorkgears.com

tel: +39 0331 552128


fax: +39 0331 553147
email: info@rotorkgears.it

tel: 0086-21-64348388
fax: 0086-21-64348366
email: info@rotorkgears.com.cn

A full listing of our worldwide


sales and service network is
available on our website at

Rotork Valvekits
Brookside Way,
Nunn Park,
Huthwaite,
Nottinghamshire, NG17 2NL
England

Rotork Gears India


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

Formerly RGi112E. As part of a process of ongoing product development, Rotork reserves


the right to amend and change specifications
without prior notice. Published data may be
subject to change.

www.rotork.com

tel: +44 (0)1623 440211


fax: +44 (0)1623 440214
email: sales@rotorkvalvekits.com

tel:
+91 80 3098 1600
fax:
+91 80 3098 1610
email: sales@rotork.co.in

The name Rotork is a registered trademark.


Rotork recognizes all registered trademarks.
Published and produced in the UK by Rotork
Controls Limited. POWSH0810

For the very latest version release, visit our


website at www.rotork.com.

PUB028-003-00 Issue 08/10

124

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.

ABBs 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.

Enclosed Switches

Motor Disconnects

OSHA Lock Out/Tag Out


OSHA 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.
ABBs enclosed disconnects are equipped with selector or pistol grip
handles which are padlockable and defeatable with clear position indication.

The Nema 4X rated switches from ABB


Ideal for Food and Beverage Processing machinery, ABBs 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.
ABBs Nema 4X Enclosed Switch Portfolio includes
both stainless steel and plastic options.

125

126

--


TM

--
-
-

-
TM TM -

-
-

-
---


-

- -
- - -


-

- -
--
-
- -
-
-
--
- -
-
--
- -
- -- -
--
--

- -

--

--

--

127

--


TM


-- -

-- -

--

M
M

- -
-

--

--

--


- -
- --


-- -
-- -
--

- -- -
-
- -- -- - -
-- -- - -

128

- -- -- - - -- - ---

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.
RG-IW-002
Issue 07/10

129

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. Manganese Bronze

Worm Shaft

Carbon Steel as standard, optional Stainless Steel.

Indicator plate

Carbon steel, optional Stainless Steel.

Screws (External)

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 120C:


LX-EP2 (High temp) max temp 160C:
NO-TOX EP2 (Food) max temp 204C:
MO2 (Graphite) max temp 120C:
G110 (Nuclear) max temp 150C:
G130 (Nuclear) max temp 150C:
LST 0 (Oil for MTW,MOW) max temp 135C:
EPLITH 00 (MTW) max temp 120C:

Ignition temperature > 250C


Ignition temperature > 250C
Ignition temperature > 250C
Flash point > 200C
Flash point > 200C
Flash point > 200C
Ignition temperature > 250C
Ignition temperature > 250C

Seals

Nitrile (Standard) max temp 150C:


Viton (High temp/ Nuclear) max temp 200C:
Fluorosilicone (Low temp) max temp 225C:
Silicone sealant max temp 200C:

Ignition temperature > 300C


Ignition temperature > 315C
Ignition temperature > 300C
Ignition temperature > 450C

Gearbox Detail

Gearbox Specification

Gearbox design Life

IW:
MTW:
MOW:

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 N/A

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 ratios
greater than 720:1 to operate at this speed)

N/A

10000 cycles at one third maximum torque


10000 output revolutions at one third maximum torque
2 years or 17,520 hours continuous operation

Maximum bending moment on the input flange

F10:
F14:
F16:
F25:
F30:

200Nm (IW8, used on 54" Valves)


340Nm (IW5, used on 14", 16", 18", 20" Valves)
520Nm
1450Nm
1580Nm

Maximum operating temperature

Indicated on the nameplate

Gearbox weight

Indicated on the nameplate

C.F. 07.07.06 issue 3


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

130

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 customers 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.
2.
3.

The valve spindle must be greased before assembly of the gearbox to the valve.
Flanges to be sealed on assembly with silicone sealant.
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 manufacturers 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
SCREW
SIZE

TORQUE
TIGHTNESS
(Nm)

TORQUE
TIGHTNESS
(lbsft)

2
5
9
21
41
71
177
346
598

2
4
6
15
30
53
131
255
441

M4
M5
M6
M8
M10
M12
M16
M20
M24
M30
M36

HEXAGON HEAD GRADE 8.8


WITH NORDLOCK WASHER
TORQUE
TORQUE
TIGHTNESS
TIGHTNESS
(Nm)
(lbsft)

3
6
10
25
49
86
213
415
718

2
4
8
18
36
63
157
306
529

SOCKET HEAD GRADE 12.9


TORQUE
TIGHTNESS
(Nm)

TORQUE
TIGHTNESS
(lbsft)

4
8
14
35
69
121
299
584
1009
2006
3508

3
6
11
26
51
89
221
431
744
1480
2587

SOCKET HEAD GRADE 12.9


WITH NORDLOCK WASHER
TORQUE
TORQUE
TIGHTNESS
TIGHTNESS
(Nm)
(lbsft)

5
10
17
42
83
145
359
701
1211

4
7
13
31
61
107
265
517
893

DURLOK GRADE 12.9


SCREW GRADE 12 NUT
TORQUE
TORQUE
TIGHTNESS
TIGHTNESS
(Nm)
(lbsft)

11
19
45
86
152
372
717

8
14
33
64
112
274
529

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

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
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.1.7
4.1.8
4.1.9
4.1.10
4.1.11
4.1.12
4.1.13
4.1.14
4.1.15
4.1.16

If the worm gearbox is fitted with an input reducer see the dismantling instructions for the input
reducer to first remove the input reducer.
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.
Fully remove the output sleeve screws (11) from indicator plate (8).
Remove the indicator plate (8) and o rings (28).
Remove the output sleeve (5) where applicable.
Remove the key (20) from the worm shaft (4).
Remove the screwed fasteners (17), which secure the input housing (7) to the gearcase (1).
Remove the input housing from the gearcase.
The worm shaft can sometimes be removed at this stage by unscrewing the worm from the wormwheel
(3).
Remove the screwed fasteners (27) that secure the baseplate (2) to the gearcase.
Remove the baseplate from the gearcase.
Remove the wormwheel (3) from the gearcase.
Remove the screwed fasteners (18) that secure the end cap (6) to the gearcase and remove the end cap.
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.
Remove bearings from the input housing, end cap or gearcase.
Loosen the lock nuts (16) and remove the stop bolts (15) from the gearcase where applicable.

4.2 Re-assembly
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
4.2.8
4.2.9
4.2.10
4.2.11
4.2.12
4.2.13
4.2.14
4.2.15
4.2.16
4.2.17
4.2.18

Ensure all parts are free from dirt and bruising


On re assembly, all moving parts should be lightly lubricated with grease before refitting.
Ft the o ring (14) to the gearcase.
Fit the bearing(s) in the end cap or within the gearcase, making sure that the bearing is orientated
correctly and packed with grease.
Fit the o ring or apply sealant (25) to the end cap and secure to the gearcase with the screwed
fasteners.
Re-fit the worm shaft into the gearcase and locate with the bearing contained by the end cap.
Fit the bearing(s) in the input housing or within the gearcase, making sure that the bearing is orientated
correctly and packed with grease.
Fit the o ring (12) to the input housing.
Fit the o ring or apply sealant (25) to the input housing and secure to the gearcase with the screwed
fasteners.
Grease the worm shaft and gearcase before refitting the worm wheel.
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.
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.
Re-pack the gearcase with grease.
Fit the o ring or apply sealant (26) to the baseplate and re-fit the baseplate into the gearcase.
Re-secure the gearcase to the baseplate using the existing screws (27) using a diagonal tightening
movement.
Fit the o ring (13) into the baseplate.
Fit the output sleeve into the gearcase where applicable.
If o rings (28) are used with the output sleeve, position the o rings in the countersink holes of the
output sleeve.

C.F. 30.07.10 Issue 3


F:\Exeeco\GBOX\ENGINEER\ATEX\Instructions\Worm\Dismantle & Reassemble WormR3.doc

132

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:
Torque tightening figures.
Procedure for replacing old style output sleeves
Gearbox Installation Manual

IWSPARES.
Document No QC 40-2
IW-OS1
RG-INSTALL

C.F. 30.07.10 Issue 3


F:\Exeeco\GBOX\ENGINEER\ATEX\Instructions\Worm\Dismantle & Reassemble WormR3.doc

133

SPARE PARTS LIST FOR IW RANGE OF WORM GEAR ACTUATORS


25

21

17

10

18

22

12
6

20

11
23

13

FITTED TO
UNDERSIDE OF
INDICATOR PLATE

16
27
14
26

19

28

15

PART SECTION

SECTION
11
19
ITEM

DESCRIPTION

QTY

SPARES

GEARCASE

BASEPLATE

WORM QUADRANT

WORMSHAFT

OUTPUT SLEEVE

1 (IW3 -11 ONLY)

ENDCAP

INPUT FLANGE

INDICATOR PLATE

ANGULAR CONTACT BALL BEARING

2 (IW3-8), 6 (IW9 -11), 4 (IW12-13)

YES

10

SHIM

1 (WHERE APPLICABLE)

YES

11

SOCKET HEAD CAP SCREW/ DURLOCK

4 (IW3, IW12-13), 8 (IW4 -11)

12

O-RING

YES

13

O-RING

YES

14

O-RING

YES

15

STOP BOLT

2 (IW & MOW ONLY)

16

HEX NUT

2 (IW & MOW ONLY)

17

SCREWED FASTENER *

4 (IW3 - 8), 8 (IW9 - IW13)

18

SCREWED FASTENER *

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

22

RIVET 4 X 3/16"

2 FOR METAL NAMEPLATE ONLY

23

LABEL - SHCS/NORDLOCK WASHER

28
18

23

5
22
14
21

25

1
10

16

15

24*

GREASE

TO FILL GEARBOX

25

O-RING OR SEALANT

YES

26

O-RING OR SEALANT

YES

27

SCREWED FASTENER *

4 (IW3), 8 (IW4-10), 16 (IW11-13)

28

O RING

4 (IW3), 8 (IW4 - IW11)

YES

13

9
25

26

7
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 HAVE
THE SAME GEARBOX RATING

Rotork Gears
Regina House
Ring Road
Bramley
Leeds
England
LS13 4ET

17

20

27

TYPICAL WORM EXPLODED VIEW

C.F. 27.07.10 ISSUE 3


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

134

12

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)

1. See Fig. 1
2. 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.

1
2
3

1
2

Fig.1

4. See Fig. 2
5. 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 4.2 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
1
washers, to the torque indicated on the switchplate cover.
14. See Fig 4.
2

Fig.2

12
6

11

10

8
9
7

Fig. 4

Fig. 3

Rotork Gears
Regina House
Ring Road
Bramley
Leeds
England
LS13 4ET

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.

Ref: CA15 (Namur Mounting Kit Instructions)

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

SPARE PARTS LIST FOR IW RANGE OF WORM GEAR ACTUATORS


25

21

17

10

18

22

12
6

20

11
23

13

FITTED TO
UNDERSIDE OF
INDICATOR PLATE

16
27
14
26

19

28

15

PART SECTION

SECTION
11
19
ITEM

DESCRIPTION

QTY

SPARES

GEARCASE

BASEPLATE

WORM QUADRANT

WORMSHAFT

OUTPUT SLEEVE

1 (IW3 -11 ONLY)

ENDCAP

INPUT FLANGE

INDICATOR PLATE

ANGULAR CONTACT BALL BEARING

2 (IW3-8), 6 (IW9 -11), 4 (IW12-13)

YES

10

SHIM

1 (WHERE APPLICABLE)

YES

11

SOCKET HEAD CAP SCREW/ DURLOCK

4 (IW3, IW12-13), 8 (IW4 -11)

12

O-RING

YES

13

O-RING

YES

14

O-RING

YES

15

STOP BOLT

2 (IW & MOW ONLY)

16

HEX NUT

2 (IW & MOW ONLY)

17

SCREWED FASTENER *

4 (IW3 - 8), 8 (IW9 - IW13)

18

SCREWED FASTENER *

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

22

RIVET 4 X 3/16"

2 FOR METAL NAMEPLATE ONLY

23

LABEL - SHCS/NORDLOCK WASHER

28
18

23

5
22
14
21

25

1
10

16

15

24*

GREASE

TO FILL GEARBOX

25

O-RING OR SEALANT

YES

26

O-RING OR SEALANT

YES

27

SCREWED FASTENER *

4 (IW3), 8 (IW4-10), 16 (IW11-13)

28

O RING

4 (IW3), 8 (IW4 - IW11)

YES

13

9
25

26

7
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 HAVE
THE SAME GEARBOX RATING

Rotork Gears
Regina House
Ring Road
Bramley
Leeds
England
LS13 4ET

17

20

27

TYPICAL WORM EXPLODED VIEW

C.F. 27.07.10 ISSUE 3


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

148

12

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