Professional Documents
Culture Documents
Rotork A Range - Installation and Maintenance Manual PDF
Rotork A Range - Installation and Maintenance Manual PDF
5 Setting instructions
5.1 Switch mechanism
5.1.1 How to check if your actuator has
already been properly set
5.1.2 Setting the limit switches to operate at
either end of valve stroke
5.1.3 Selecting torque or limit control
5.1.4 How to select torque values
5.1.5 How to replace switch mechanism cover
5.2 Optional extras
5.2.1 Setting intermediate auxiliary switches
(AOP1 only)
5.2.2 Setting the potentiometer
5.2.3 Setting the Current Position transmitter
(CPT)
5.2.4 Blinker
5.2.5 Folomatic proportional control
(Syncropak only)
5.2.6 Interrupter Timer (Syncropak only)
5.2.7 PA Failsafe actuators
Rotork Syncroset actuators Rotork Syncropak actuators
Each standard Synchroset Each standard Syncropak
consists of four basic sub- consists of four basic sub-
assemblies: assemblies:
a Motor a Motor
b Oil-filled worm gearbox with b Oil-filled worm gearbox with
handwheel and declutch handwheel and declutch
mechanism mechanism
c Limit and torque switch c Limit and torque switch
mechanism mechanism
d Terminal box Inegral Syncroset d Integral starter and associated
control equipment
Syncroset DC
Standard Syncroset
Standard Syncropak
(or Flameproof Syncoset with
Pushbuttons)
Loosen set screw and unscrew Fit drive bush retainer securely,
retainer using hammer and turning clockwise until fully
punch. Remove drive bush and tightened using hammer and
machine to suit valve stem or punch. Rotate by handwheel to
gearbox input shaft. align retainer set screw with hole
Type A drive bush in position 2 in base and lock tight.
Allow apparently excessive
clearance on screw thread for old If it has a type AZ drive bush this
rising stem valves can only be fitted below the
actuator base to give the
maximum stem diameter
acceptance.
4.3 Sealing conduit entries 5.1 Switch mechanism 5.1.2 Setting the limit switches
to operate at either end of valve
Conduit entries should be sealed There are two basic operations stroke
in accordance with surrounding which have to be carried out:
environment and Note: Instructions are for
with any requirements of the 1 Setting the switches to operate 'clockwise closing'. For
regulatory authority. at either end of the valve's stroke 'anticlockwise' read 'opening' as
'closing' etc.
Seal unused entries with 2 Selecting the correct 'torque' or
threaded metal plugs. Do not use 'limit' function for your particular
plastic plugs if supplied with valve and possibly adjusting the
actuator. torque value for your particular
application.
4.4 Connecting terminals
If you have already received a
Refer to the wiring diagram inside complete motorized valve these
the terminal cover to identify operations should already have
functions of terminals. Check that been carried out.
supply voltage is the same as
marked on the code card and 5.1.1 How to check if your
actuator nameplate. Remove actuator has already been
transparent power terminal properly set
screen, and begin wiring the Mount your actuator on the valve,
power terminals. With the actuator firmly bolted to see section 3. Remove the switch
the valve engage handwheel mechanism cover as follows:
Note: Syncroset and Syncropak drive.
1400 series Remove the three retaining
Fully open the valve by hand and screws adjacent to gear case
Correct phase rotation is check that the position indicator using a 5/32" AF Allen key. (5mm
essential for electrical operation pointer moves over to the 'open' if cenelec enclosure.)
and must be checked at start-up position just before the
stage. All Rotork Syncroset and handwheel reaches its stop. Pull off cover squarely with both
Syncropak 1400 series 3 phase hands. Do not attempt to lever
actuators are tested for correct Fully close the valve by hand and cover off with a screwdriver. This
operation with phase rotation in check that the pointer moves over is likely to damage the 'O' ring
terminal order 1,2,3. to the 'shut' position just as the and may also damage the flame
valve seats. path on a certified unit.
4.5 Replacing terminal cover
If the indicator is reading correctly Engage handwheel drive. (see
Check that serial number on code at both ends of stroke, you can section 1.)
card is the same as on the assume that your valvemaker has
actuator nameplate before already carried out the detailed
replacing cover with its 'O' ring in setting instructions which follow
position. and you can proceed directly to
Section 6 Start-up.
After fully tightening clutchnut, Now wind the valve open as far
you can release your pressure on as mechanically possible. Do not
the overtravel guide. Apart from then wind it back a fraction 'for
Turn actuator handwheel until safety's sake'.
nominal backlash on releasing
valve is closed as far as
pressure, the overtravel guide
mechanically possible. Using one finger, pull overtravel
should not move away from stop
and the switches should not be guide (20) over clockwise, until it
Turn screwed shaft 15 comes hard up against its stop
heard to reset. If you hear a
anticlockwise with your fingers (21). Keep it hard over in this
'click' at this stage you have not
until you feel the travelling nut position. Switches will have been
carried out the preceding
comes hard up against its heard to click during this
instructions correctly.
backstop 19. operation.
The 'close' switches are now set
Gripping screwed shaft between With overtravel guide still held
so that they trip just before the
your thumb and first finger you hard over, run locknut 17
mechanical stop is reached. For
will be able to continue to turn it, clockwise down screwed shaft
valves with limit functions on
by using the overtravel guide 20 until it comes up hard against
closing, check shut position by
for leverage. Continue to turn travelling nut.
operating electrically. If valve
until overtravel guide comes up
does not fully shut, handwind to
against overrun stop 21. Push washer 24 down screwed
mechanical stop, loosen clutchnut
22 and allow overtravel guide 20 shaft until it is against locknut 17
During this final movement you then run locknut 18 down until it
to return to neutral position. Turn
will have heard the switches click. clamps both locknuts and washer
screwed shaft 15 anticlockwise,
with the aid of overtravel guide, to together. Lightly tighten locknut
Holding overtravel guide hard 18.
just beyond position where all
over against its stop, tighten
switches are heard to operate but
clutchnut.
before overtravel guide hits stop
21. Tighten clutchnut and ensure
switches do not reset when guide
is released.
Release pressure on overtravel If necessary, dial selectors C and Selector B which controls opening
guide. Overtravel guide should D to suit your particular valve. torque should be dialled to MAX
stay put against stop and unless the valvemaker's specific
switches should not be heard to Select the correct torque or limit instructions recommend against
reset. if a 'click' is heard after functions for your valve as this.
releasing the pressure on the follows:
overtravel guide you have not Torque setting adjusters are fitted
carried out the preceding If you have bought a complete with locking tabs to discourage
instructions correctly. motorized valve, your valvemaker unauthorised tampering with
will probably have made the original settings. After adjusting
The 'open' switches are now set. correct torque or limit selection to 'open' and 'close' torque to
By following the procedure suit his own valve. required value, lock setting by
exactly you have ensured: bending up appropriate tabs each
In the absence of specific side of pointer. If no open torque
1 That the switches are set to cut valvemaker's instructions, use the limit is required, turn open torque
off the motor before the valve following basic table: adjuster pointer to boost position,
reaches its end of travel and that where no locking is required.
the motor has time to come to Valve type 'close' 'open’
rest. 5.1.5 How to replace switch
Wedge gate 'torque’ 'limit’ mechanism cover
2 That manual operation of the or globe
valve can never alter the switch Ensure that indicator lamp
operating point which you have butterfly, thru 'limit' 'limit’ support, if fitted, is central.
set. conduit ball, Ensure that O-ring is in good
plug, sluice gate condition (spare may be found in
5.1.3 Selecting torque or limit or parallel slide terminal box).
control
Offer cover up squarely to spigot,
Check if the correct torque or limit 5.1.4 How to select torque register and push on. Tighten the
functions have already been values three securing screws.
selected as follows:
Selectors A and B adjust the
With the switch mechanism cover amount of torque which can be
still removed check the position of applied to the valve before the
the 'open' and 'close' torque/limit torque switch cuts out the motor.
selectors. They should tally with
Ideally, only the minimum torque
the torque or limit positions on the necessary to achieve tight shut-
table below, or with your off should be applied. In practice
valvemaker's specific instructions. this value will vary from valve to
valve and fluctuate with
temperature, use, service etc.
CPT span
a Check whether valve is
Link J17
clockwise or anti-clockwise to
close. Spare fuse
Diagnostic socket
Primary fuse
b Using fig. A overleaf locate the ‘On’ time
Folomatic switch 1
dual links J7. For clockwise to adjust
close valve with low signal at Deadband
open, link J7 must be positioned Time range
switches 1 - 4 Zero
parallel to the edge of the PCB.
‘Off’ time Span
adjust
c For clockwise to close valves Switch 2
with low signal at open, and for
anti-clockwise to close with low Secondary fuse
13 Check that cable glands are Setting instructions Refer to Rotork publication
tight and any unused entry sealed E271E (AE5/8) for coupling
with threaded metal plug and A pair of potentiometers will be details.
sealing tape. If possible pour found behind the pushbutton
sealing compound into conduit cover. See fig.A. They are
entries from inside terminal marked 'on' and 'off' and are used
compartment to perfect weather to set the on/off times of
seal. operation.
Check that limit switches have If actuator stops prematurely it Correct phase rotation as
been set; see section 5. may be due to too low a torque follows:
setting. Increase as necessary;
All actuators (except Syncropak see section 5. 3 phase actuators
1600 series) Exchange any two of three phase
For valve requiring precisely supply leads at power terminals.
6.1 Checking rotation controlled position limit, check
that valve maker's mark on valve DC actuators
If valve stem is not visible, is reached. If it is not this is due Exchange connections at
remove stem cover to observe to incorrectly set limit switches; terminals 1 and 2.
direction of output rotation. see section 5.
Single phase actuators
Engage 'hand' and wind Replace stem cover using Exchange connections at power
handwheel until valve is well suitable sealing tape or terminals 2 and 3.
away from end position. compound and return selector
switch to appropriate position. 6.4.1
6.2 Syncropak 1400 series Padlock if required.
actuators If valve opens, run valve to full
6.3 Syncropak 1600 Series travel in 'open' and 'close'
Switch on power supply and actuators directions.
check that indicator lamp is on. Syncropak 1600 Series
incorporates automatic phase If the actuator stops prematurely
Remove padlock (if fitted) and rotation by Syncrophase. it may be due to too low a torque
turn selector switch to 'local'. setting. Increase as necessary;
This circuit corrects motor see section 5.
Turn pushbutton to 'open' and rotation, by selecting the
check output rotation. appropriate motor contactor For valves requiring precisely
irrespective of customer's supply controlled position limit, check
If phase rotation is correct valve phase rotation. that valve marker's mark on valve
should open. If valve starts is reached. If it is not, this is due
closing press pushbutton 6.4 Syncroset actuators to incorrectly set limit switches;
immediately to stop actuator and see section 5.
avoid valve damage or jamming. Switch on power supply. If there
are no pushbuttons within sight of Replace stem cover using
If your actuator has been fitted the actuator arrange telephone suitable sealing tape or
with a Rotork Phase Rotation link between control station and compound.
Discriminator to avoid such the observer at the actuator.
accidental damage, it will not start
with incorrect phase rotation or Press 'open' button.
with one phase dead.
If connections are correct valve
Correct phase rotation as follows: should open.
3 phase actuators
Exchange any two of three phase If the valve starts closing stop
supply leads at power terminals; immediately. If there is no local
see section 4. stop, engage hand immediately
and hold in hand drive until
Single phase actuators remote stop button is operated.
Exchange connections to
terminals 2 and 3.
7.1 Syncropak actuators Check transformer fuses and Actuator runs without driving
replace if necessary with spare valve
The starter cover is bonded by provided. Likely causes:
the Rotork quality control seal,
and should only be removed if Note: 1400 series only: The 1 Clutch lever padlocked in
electrical tests made at the diagram number on wiring code 'hand'.
terminal box indicate an internal card inside cover will indicate if
fault. Phase Rotation Discriminator is 2 Drive bush not correctly locked
fitted, in which case actuator will in place; see section 2.
Check that the clutch lever is not not start with incorrect rotation.
padlocked in hand before trouble Exchange any two phases and try
shooting unless you wish to run again.
the motor without driving the
valve. 7.3 All actuators
Oil capacities
7A, 11A, 13A: 0.6 litre
14A, 16A: 1.4 litre
30A:2.0 litre
40A: 3.0 litre
70A, 90A, 91AR, 95A: 4.5 litre Oil fill/drain plugs
The use of the plugs provided is After six month's operation tighten
determined by the mounting mounting bolts.
position on the valve.
If your Rotork actuator has been
properly installed and sealed,
normal valve operation produces
little wear and tear, so no routine
maintenance is recommended
beyond the lubrication of valve
stems and nuts. If the motorized
valve is rarely operated, a routine
operating schedule should be set
up.
Off
On
Off/On
mail@rotork.co.uk