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Workshop and Spare Parts Manual

IQ Mk 3 Range Actuators
Module 1A Gear Case Complete All mechanical sizes.
Publication 002-047-00 issue 06/13

Module 1A Gearcase consists of


the following components and modules:-
Gearcase Casting with Seals and Bearings.

Note: Module 1D is NOT Included but is


available separately.

Module 1B
Centre Column, Encoder Drive, Clutch
Assembly, Clutch Spring.

Module 1B/1
Spring and Sliding Coupling.

Module 1C
Encoder Drive Mechanism. Oil Seals,
Module 1A Gearcase Sizes 10,12,18,20,25 and 35. Drive Shaft and Gear.

Module 1D
Encoder Assembly Only.

Module 1E
Wormshaft and WormWheel Maintenance
Kit, ’O’ Rings, Seals, Bearings, Fixings etc.

Module 1F
Gearcase Maintenance Kit ‘O’ Rings, Seals,
Bearings, Screws etc.

Module 1G
Hand/Auto lever and Cam, Spring, ‘O’ Rings.

Module 1G/1
Hand Auto Kit (No Lever), Cam, Spring,
‘O’ Rings.

Module 1J
Torque Transducer Assembly.
Module 1A Gearcase Sizes 40,70,90, 91 and 95.

Module 1K
Battery Assembly.
WARNING Removal Strap, Battery and Cover Plug.

This replacement Gearcase Module 1A includes a Module 1K/1


new but uncalibrated torque transducer. Before Battery only.
running the actuator electrically the transducer must
be calibrated to suit this actuator. To achieve this Module 1L
please contact your nearest Rotork service centre Battery Cover plug only
and request this service. Running the actuator
without calibration could result in the valve being
damaged.

Full details from the actuator name plate must be given when enquiring about or ordering spare parts
Publication 002-047-00 issue 11/12
Module 1A Gearcase All mechanical sizes
Publication 002-047-00 issue 06/13

Removing Actuator Removal of Actuator


from Valve from Valve Gearbox

WARNING Take weight of the actuator on


Before dismantling the actuator the sling before removing the
isolate and disconnect incoming Pic 26 actuator to gearbox fixings.
electrical supply to actuator. Actuator should slide off
Remove and retain any gearbox input shaft, ensure
adaptors or reducers from the sling is holding the weight of the
threaded cable entries. actuator at all times.
Actuator sizes 12-95 can be
removed from their bases
leaving this to maintain the
valve position. In this case the
base must be protected from
the environment.
Remove Drive Bush
Alternatively, the actuator and
base can be removed as one IQ sizes 10 to 95
piece.
Group ‘A’ Bases and
Pic 27
Drive Bushes
(Types A, Z3 )

To remove the thrust base from


the actuator first remove the
Remove Actuator from stainless steel securing bolts,
retain these for refitting later.
Valve or Gearbox

WARNING
Actuator Weights
ONLY PERSONS COMPETENT
BY VIRTUE OF THEIR TRAINING
AND EXPERIENCE SHOULD BE 10,12,18 = 31Kgs / 68lbs
ALLOWED TO REMOVE
ACTUATOR FROM THE VALVE 20,25 = 54Kgs / 119lbs
OR GEARBOX.
35 = 75Kgs / 165lbs
AS THE ACTUATOR MAY BE
40, 70 = 145Kgs / 320lbs
INSTALLED AT ANY ANGLE,
CORRECT SLINGING OF THIS
UNIT MUST BE JUDGED IN 90, 95 = 160Kgs / 353lbs
EACH INDIVIDUAL CASE.
91 = 150Kgs / 331lbs

Actuator Direct
Mounted onto Rising
Stem Valves
WARNING
Ensure pressure is removed
from pipeline, move valve Pic 75
‘open’ a short distance to
eliminate any locked in
pressure, close the valve fully.
Take the weight of the actuator Size 10,12,25 (F10 , FA10) Sizes 40 to 95 (F25 & F30)
on the sling before removing A Type Thrust Base A Type Thrust Base
the actuator to valve fixings,
wind the handwheel in the
‘close’ direction when actuator
will move up the valve stem,
ensure sling is holding the
weight at all times.
Publication 002-047-00 issue 11/12
Module 1A Gearcase All mechanical sizes
Publication 002-047-00 issue 06/13

IQ sizes 10 to 95 Top Handwheel


Assembly
Remove ‘B’ Type Base
Locate and remove the 3 fixing
Remove the Flange to Actuator screws locating the Cover Tube
Gearcase fixing bolts and lift off or Blanking Cap to the
the flange. handwheel assembly.

Remove Top Handwheel


Using the correct size circlip (If fitted)
pliers open the circlip and
remove, coupling can now be Locate and remove the fixing
knocked out from the screws locating the handwheel
handwheel end. hub assembly to the gearcase.

Oil Plugs - Drain Oil


Check that the condition of the
To drain the oil, remove the two ‘O’ Ring and the sealing face is
plugs situated in the gearcase. satisfactory.
Renew if necessary.
The oil may be drained from the
gearcase after the top or side Retain the assembly for refitting
hand wheel assembly is to the new Gearcase.
removed.

Drain/fill plugs

Remove Cover Tube or Remove Side


Hub Sealing Cap. Handwheel (If fitted)
(If fitted)
Locate and remove the fixing
The top or side handwheel screws locating the side
assembly should be fitted with handwheel hub assembly to the
a Cover Tube or Sealing Cap gearcase
to help prevent ingress of
moisture to the centre column Check that the condition of the
area. ‘O’ Ring and the sealing face is
satisfactory.
Renew if necessary.

Retain the assembly for refitting


to the new Gearcase.
Module 1A Gearcase All mechanical sizes

Publication 002-047-00 issue 06/13

Remove Electronics Locate the two retaining clips


Module. on either side of the chassis
mounts.

Depress the clips and carefully


remove the Logic Control PCB
together with its mounting ring
from the two chassis retaining
legs.
Position the two legs to the
sides to aid removal.
Note its position relative to the
gearcase to ensure correct
alignment when refitting
replacement module.
Remove Electronics
Cover Move the two chassis legs
outboard towards the casting.
Using a 6mm allen key (hex There is no need to remove
wrench) remove the four cap them at this stage.
head screws securing the
electronics cover. Take note of cable routeing so
If necessary fit two of these that it can be refitted in exactly
screws into the threaded holes the same position on
in the cover to jack it out. reassembly.

Disconnect all remaining cables


Care must be taken in from the Logic Control PCB and
removing this cover as there is any option cards fitted to it, note
an electrical cable between it their positions for ease of
and the Logic Control PCB. reassembly.

Disconnect the plug and Retain for fitting to the new


socket. Retain this cover and Gearcase Assembly.
‘O’ ring seal for fitting to the
new Gearcase Assembly. Push back the two chassis
legs .

The legs may be removed from


the chassis at this stage.

Remove Main PCB


Disconnect the ribbon cable
located on the right hand side of
chassis from the Logic Control
PCB to the power supply
module.

Disconnect Power
Module (3 Phase)
Disconnect any cables and Disconnect all cables going onto
looms connected to the top of the contactors taking note of
the Logic Control PCB and any their positions:-
Option cards if fitted. 3 Phase Power marked 1-2-3.
3 Phase Motor marked U-V-W.
Coils marked C1-C2-CC.
Module 1A Gearcase All mechanical sizes

Publication 002-047-00 issue 06/13

Disconnect Power Lift the module carefully away


from the gearcase.
Module (Single
Phase) Note: that there are cables
connected to the rear of the
Disconnect all cables going assembly.
from the terminal
compartment to the
capacitors and solid state Disconnect any looms connected
start relay taking note of to SKT 2 & SKT 4
their positions.

Remove the loom connected to


Remove Power the Encoder and retain for fitting
Module later.

Before removing power Disconnect the Earth (Ground)


module take note of the Link from the casting.
cable routeing so that it can
be replicated when fitting
replacement.

Using a 5mm Allen wrench Using a 5 mm Allen wrench


locate and remove the five locate and remove two encoder
power module fixing screws. fixing screws.
The encoder can now be
withdrawn from the gearcase and
retained for refitting.

Note

IQ Sizes 40 to 95

The contactor size is larger


however the removal
procedure is the same.
Publication 002-047-00 issue 11/12
Module 1A Gearcase All mechanical sizes
Publication 002-047-00 issue 06/13

Remove Terminal
Cover
Using a 6mm allen key (hex
wrench) loosen the four
securing screws and remove
cover. The screws are captive
and will remain in the cover,
retain this cover for refitting.

Remove Terminal Bung


Locate and remove the terminal
bung securing clip. Retain this
clip for refitting.

The terminal bung can now be


pulled out of the casting
complete with the cable looms.

Retain the bung assembly for


refitting.
Publication 002-047-00 issue 11/12
Module 1A Gearcase
IQ, IQS, IQM, IQML 10, 12, 18, 20, 25 & 35 Only
Publication 002-047-00 issue 11/12

Remove Motor Cover Disconnect Torque


Transducer
Before removing motor stator
cover mark its position relative Using an Allen Wrench remove
to the top of the gearcase. the 2 screws securing the plastic
mounting bracket to the torque
transducer thrust plate.

Disconnect the loom connected


Remove and retain the four cap to the torque transducer.
head screws, slide the stator off
the gearcase.
Explosionproof Units
Be careful not to damage only
Motor and Torque Transducer (CENELEC/FM/CSA)
wiring during removal.
In explosionproof units there is a
black plastic cable retainer
clipped onto the thrust retaining
plate. This must be retained for
refitting.

Do not mislay the coil spring at Remove the 3 fixings locating the
the outboard end of the rotor thrust plate to the gearcase.
shaft. Retain for refitting.

Explosion Proof Units Only.

Explosion-proof wiring looms


are fitted with a steel transfer
bush, this is a certified flame
path and must not be scored or
damaged in any way.

Motor Rotor Remove the Motor and Torque


Transducer wiring loom and retain
Using an allen key (hex wrench) for refitting.
and a hex socket remove and
retain the bolt and nut securing All components have
the rotor shaft to the worm now been removed for
shaft, slide the rotor shaft off transfer to new Module
and retain in a safe place for
refitting. 1A Assembly.

Go To Re-Assembly
Page
Publication 002-047-00 issue 11/12
Module 1A Gearcase
IQ, 40, 70, 90, 91 & 95 Only
Publication 002-047-00 issue 06/13

Slide rotor off the shaft and


Remove Motor Stator retain all components for
refitting.
WARNING
It is advisable to support the
weight of the motor as it WT Units Only
could weigh up to 70Kg
(154lbs). Remove the Motor and Torque
Transducer wiring loom and
retain for refitting.
Before removing motor stator
mark its position relative to the
gearcase.

Remove and retain the four cap Explosionproof Units


head screws, slide the stator only
out of the gearcase onto the
work surface. (CENELEC/FM/CSA)
In explosionproof units there is
a black plastic cable retainer
Be careful not to damage clipped onto the thrust retaining
Motor and Torque Transducer plate. This must be retained for
wiring during removal. refitting.

Do not mislay the coil spring at Remove the 6 fixings locating


the outboard end of the rotor the thrust plate to the gearcase
shaft. Retain for refitting. to allow removal of the Motor
and Torque transducer wiring
loom and retain for refitting.

Explosion Proof Units Only.

Explosion-proof wiring looms


are fitted with a steel transfer
bush, this is a certified flame
path and must not be scored
or damaged in any way.

Motor Rotor All components have


now been removed for
Using a 36mm wrench remove
hex nut on end of rotor shaft. transfer to new Module
Now remove locking washers 1A Assembly.
and taper coupling.

Note
Carefully remove drive key from
end of rotor shaft.
Publication 002-047-00 issue 11/12
Module 1A Gearcase All mechanical sizes
Publication 002-047-00 issue 06/13

Reassembly Refit Terminal Cover

All reusable components have First check that the spigotted


been removed from the original joint is clean, lightly greased
gearcase module 1A and can and the ‘O’ ring seal is
now be fitted into the serviceable .
replacement module in the
following order. Tighten screws down to 16Nm
(12lb/ft).

Refit Terminal Bung


and Cable loom

First check that the bung ‘O’


ring is in position and lightly
greased.

Feed the cable into the


gearcase and through into the
electronics compartment.

Lightly tap the bung into


position in the gearcase with
the terminal No: 4 adjacent to
the centre cable entry, fit bung
retaining clip.
Publication 002-047-00 issue 11/12
Module 1A Gearcase
IQ, IQS, IQM, IQML 10, 12, 18, 20, 25 & 35 Only
Publication 002-047-00 issue 06/13

Refit Motor
Fit coil spring onto outboard end
of rotor shaft.
Feed the motor cables through
into the electronics
compartment.
Fit Motor Stator to
Explosionproof Units Gearcase
Only
(CENELEC/FM/CSA)
Before fitting motor ensure the
Remove the 3 fixings locating spigotted joint is clean and
the thrust plate to the gearcase, lightly greased and that the ’O’
this will allow the steel transfer ring seal is serviceable.
bush and motor loom to be
fitted. Refit the thrust plate.

Explosion-proof wiring looms WT Only


are fitted with a steel transfer
bush, this is a certified flame
Slide stator over rotor shaft, do
path and must not be scored
not damage the windings, feed
or damaged in any way.
the motor cables into the
electrical compartment.
Explosionproof Units
Only
The black plastic cable retainer
can now be clicked into position
on the flange, ensure that the
cut-out aligns with the motor
cable.

Explosionproof Only
Reconnect the torque
transducer loom . Using an On these units the motor loom
Allen key wrench refit the remains in the motor
plastic mounting bracket onto compartment, to prevent it being
the transducer thrust plate. damaged it must be positioned
correctly in its plastic retainer as
follows:-
Position the stator onto the rotor
shaft, do not damage the
windings, whilst rotating the
stator anti-clockwise feed the
cables into the plastic retainer.
Ensure that the cables are
correctly positioned before
finally bolting stator casting onto
the gearbox. Screws to be
Fit Motor Rotor tightened to 16.5Nm (12lb/ft).

Slide the rotor shaft onto the


end of the wormshaft, align the
bolt hole and fit shouldered bolt
and nyloc nut, tighten to 6.8Nm.
Publication 002-047-00 issue 11/12
Module 1A Gearcase
IQ 40, 70, 90, 91 & 95 Only
Publication 002-047-00 issue 06/13

Refit Motor Fit coil spring onto outboard end


of rotor shaft.
Feed the motor cables through
into the electronics
compartment.

Explosionproof Units
Only Fit Motor Stator to
(CENELEC/FM/CSA) Gearcase

Remove the 6 fixings locating


the thrust plate to the gearcase, Before fitting motor ensure the
this will allow the steel transfer spigotted joint is clean and
bush and motor loom to be lightly greased and that the ’O’
fitted. Refit the thrust plate. ring seal is serviceable.

Explosion-proof wiring looms


are fitted with a steel transfer
bush, this is a certified flame
path and must not be scored WT Only
or damaged in any way.
Slide stator over rotor shaft, do
Explosionproof Units not damage the windings, feed
Only the motor cables into the
electrical compartment.
The black plastic cable retainer
can now be clicked into position
on the flange, ensure that the
cut-out aligns with the motor
cable.

Explosionproof Only
Reconnect the torque
transducer loom . Using an On these units the motor loom
Allen key wrench refit the remains in the motor
plastic mounting bracket onto compartment, to prevent it being
the transducer thrust plate. damaged it must be positioned
correctly in its plastic retainer as
follows:-
Position the stator onto the rotor
shaft, do not damage the
windings, whilst rotating the
stator anti-clockwise feed the
cables into the plastic retainer.
Ensure that the cables are
correctly positioned before
finally bolting stator casting onto
Fit Motor Rotor the gearbox. Screws to be
tightened to 16.5Nm (12lb/ft).
Slide the original rotor onto the
wormshaft, ensure the slot on
the in-board end engages with
the locating pin.

The components are fitted to


the wormshaft in the following
order:-
Rotor
Key
Cone
Locking Washers
Lock Nut
Coil Spring.
Publication 002-047-00 issue 11/12
Module 1A Gearcase All mechanical sizes
Publication 002-047-00 issue 06/13

Using a 5mm Allen wrench


Refit Electronics locate and tighten screws
Module ensuring no cables are trapped ,
tighten down fixing screws to
The electronics module 11Nm (8lb/ft).
previously removed from the
original gearcase can now be
refitted, first confirm that all
cables from the terminal bung Note
and motor loom have been
pulled through into the
electronics compartment. IQ Sizes 40 to 95

The contactor size is larger


however the replacement
procedure is the same.

Connect the Earth (ground) Reconnect motor cables


connection to the threaded boss marked U, V, W onto marked
in the gearcase. Screw to be terminals on right hand
tightened down to 11Nm (8lb/ft). contactor. Connect 3 phase
supply cables marked 2, 3, 1 to
marked terminal on left hand
contactor.

Encoder

Refit the encoder Reconnect Power


Module (Single Phase)
It is important to align
the encoder drive shaft Reconnect all cables going from
with the input socket. the terminal compartment to the
capacitors and solid state start
Using a 5 mm Allen wrench relay taking note of their
screw tighten the two fixings d original positions.
to 0.5Nm.

Reconnect the loom onto the


encoder socket.

Power Module Reconnect Main PCB

Before securing the power If legs have been removed


module into position locate the relocate onto chassis plate.
cables into their correct area. Close mounting legs back to
centre position.
Lift the module carefully into
position in the gearcase.

Note: that there are cables


connected to the rear of the
assembly.
Publication 002-047-00 issue 11/12
Module 1A Gearcase All mechanical sizes
Publication 002-047-00 issue 06/13

Reonnect all remaining cables Using a 6mm Allen key (hex


to the Logic Control PCB and wrench) tighten 4 screws to
any option cards fitted to it, note 16.5Nm (12lb/ft).
their original positions.

Fill Gearbox With Oil

Before fitting hand drive fill


gearcase with fresh oil through
the hand drive aperture, ensure
all oil drain plugs are sealed,
Take care to route the cables in that the sliding clutch coupling is
their original positions. down in the drive position and
bring the oil level up to the top
Locate the two retaining clips of the clutch but no higher.
on either side of the chassis
mounting legs. Oil Capacities
Carefully relocate the logic IQ sizes Litres US Pints
control PCB into position and 10,12,18 0.5 1
snap the retaining clips into 20,25 1 2.1
position. 35 1.5 3.2
40,70,90,91,95 3 6.3

Reconnect the ribbon cable Refit Top Handwheel


located on the right hand side of
the chassis from the logic Check the condition of the ‘O’
control PCB to the power ring is serviceable and sealing
module. face is satisfactory.

Refit Electronics cover Carefully refit handwheel


assembly ensuring ‘O’ ring is in
position .
First check the spigotted joint is
clean ,lightly greased and the Tighten down fixings with 6mm
‘O’ ring seal is serviceable. Allen (hex wrench).
Connect the cable loom from
HMI PCB to logic control PBC.

Refit cover taking care not to


trap any cables.
Publication 002-047-00 issue 11/12
Module 1A Gearcase All mechanical sizes
Publication 002-047-00 issue 06/13

Group ’B’ Bases and


Refit side handwheel Bushes
(if fitted)
Using the correct size circlip
Check the condition of the ‘O’ pliers open the circlip and
ring is serviceable and sealing relocate the drive bush onto the
face is satisfactory. centre column ensuring the clip
is located in the slot.
Carefully refit side handwheel
assembly ensuring ‘O’ ring is in
position .

Tighten down fixings with 6mm


Allen key (hex wrench)

Refit Cover Tube or


Refit flange adaptor onto
Hub sealing Cap gearcase and secure hex bolts.

The top or side handwheel


should be fitted with a cover
Tube or Sealing Cap to prevent
ingress of moisture to the
centre column area.

Torque values fitting bases

Ensure the ’O’ ring is in position


and serviceable then refit cover
tube or cap. Locate screws and
tighten using Allen key ( hex
wrench)

Cable Entries

Any cable entry adaptors/


reducers fitted to the original
Refitting Drive Bush gearcase can now be
transferred to the replacement
Group ‘A’ Bases and gearcase.
Only appropriate certified
Drive Bushes. explosionproof entry reducers
(Types A,Z3)
glands or conduit may be used
in hazardous locations.
If the actuator was originally
removed from the valve
Remove plastic transit plugs.
together with its base and drive
Make cable entries appropriate
coupling then these must be
to the cable type and size.
refitted onto the gearcase.
Ensure threaded, adaptors,
cable glands or conduit are
Carefully align the centre
tight and fully waterproof. Seal
column drive dogs into drive
unused cable entries with steel
coupling and tighten fixings.
or brass threaded plug. In
hazardous areas an appropri-
ate certified threaded plug
must me used.
Module 1A Gearcase All mechanical sizes

Publication 002-047-00 issue 06/13

Replace battery
Disconnect the existing battery and using the strap
provided pull out of its plastic holder.
Whilst the actuator is down for
maintenance it is recommended
Fit new battery into strap and push into its holder,
that its battery be changed.
reconnect.
The battery as fitted by Rotork
is generally a PP3 9 volt
Refit and tighten threaded plug after lightly greasing
Ultralife Lithium cell.
thread and checking sealing ‘O’ ring is serviceable.
For Hazardous area certified
units ONLY approved battery
types must be used.

See Below for Approved Battery


Types

BATTERY TYPES

For European hazardous area certified actuators (ATEX / IEC Ex) use a
lithium manganese dioxide battery as stated in Table 1 BELOW.

For FM and CSA certified enclosures use an Ultralife U9VL lithium


manganese dioxide battery. Equivalent, UL recognised, batteries may
be used.

For watertight (WT) actuator enclosures Rotork recommend a lithium


manganese dioxide battery, however any equivalent 9V battery may be
used.

If in doubt regarding the correct battery type, contact Rotork.

Table 1

Enclosure Type Battery Type Detail


ATEX/IEC Ex Ultralife PP3 U9VL or
Standard Temp Types U9VL-J-P Recommission the actuator using Publication Pub 002-039 and the
Rotork Bluetooth Setting Tool.
ATEX/IEC Ex Rotork Part Numbers 95-462 or
Low/High Temp 95-614

The battery is situated in its


own compartment located in the
gearcase.

Using an 8mm allen key (hex


wrench) remove the access
plug.
Workshop and Spare Parts Manual
IQ Mk 3 Range Actuators
Module 1B All mechanical sizes.
Publication 002-047-00 issue 06/13

Module 1B Centre Column Module consists


of :-

Centre Column
Worm Gear
Clutch Assembly
Seals
Bearings
Worm Shaft

Module 1B Centre Column assembly and Worm Shaft

Full details from the actuator name plate must be given when enquiring about or ordering spare parts
Publication 002-047-00 issue 11/12
Module 1B Centre Column All mechanical sizes
Publication 002-047-00 issue 06/13

Removing Actuator Removal of Actuator


from Valve from Valve Gearbox

WARNING Take weight of the actuator on


Before dismantling the actuator the sling before removing the
isolate and disconnect incoming Pic 26 actuator to gearbox fixings.
electrical supply to actuator. Actuator should slide off
Remove and retain any gearbox input shaft, ensure
adaptors or reducers from the sling is holding the weight of the
threaded cable entries. actuator at all times.
Actuator sizes 12-95 can be
removed from their bases
leaving this to maintain the
valve position. In this case the
base must be protected from
the environment.

Alternatively, the actuator and Remove Drive Bush


base can be removed as one
piece.
IQ sizes 10 to 95
Pic 27 Group ‘A’ Bases and
Remove Actuator from
Valve or Gearbox Drive Bushes
(Types A, Z3 )
WARNING
To remove the thrust base from
ONLY PERSONS COMPETENT the actuator first remove the
BY VIRTUE OF THEIR TRAINING stainless steel securing bolts,
AND EXPERIENCE SHOULD BE retain these for refitting later.
ALLOWED TO REMOVE
ACTUATOR FROM THE VALVE Actuator Weights
OR GEARBOX.
10,12,18 = 31Kgs / 68lbs
AS THE ACTUATOR MAY BE
INSTALLED AT ANY ANGLE, 20,25 = 54Kgs / 119lbs
CORRECT SLINGING OF THIS
UNIT MUST BE JUDGED IN 35 = 75Kgs / 165lbs
EACH INDIVIDUAL CASE.
40, 70 = 145Kgs / 320lbs

90, 95 = 160Kgs / 353lbs

91 = 150Kgs / 331lbs

Actuator Direct
Mounted onto Rising
Stem Valves
WARNING
Ensure pressure is removed
Pic 75
from pipeline, move valve
‘open’ a short distance to
eliminate any locked in
Size 10,12,25 (F10 , FA10) Sizes 40 to 95 (F25 & F30)
pressure, close the valve fully.
A Type Thrust Base A Type Thrust Base
Take the weight of the actuator
on the sling before removing
the actuator to valve fixings,
wind the handwheel in the
‘close’ direction when actuator
will move up the valve stem,
ensure sling is holding the
Publication 002-047-00 issue 11/12
Module 1B Centre Column All mechanical sizes
Publication 002-047-00 issue 06/13

IQ sizes 10 to 95 Top Handwheel


Assembly
Remove ‘B’ Type Base
Locate and remove the 3 fixing
Remove the Flange to Actuator screws locating the Cover Tube
Gearcase fixing bolts and lift off or Blanking Cap to the
the flange. handwheel assembly.

Using the correct size circlip Remove Top Handwheel


pliers open the circlip and (If fitted)
remove, coupling can now be
knocked out from the Locate and remove the fixing
handwheel end. screws locating the handwheel
hub assembly to the gearcase.

Oil Plugs - Drain Oil Check that the condition of the


‘O’ Ring and the sealing face is
To drain the oil, remove one of satisfactory.
the two plugs situated in the Renew if necessary.
gearcase.
Retain the assembly for refitting
The oil may be drained from the to the new Gearcase.
gearcase after the top or side
hand wheel assembly is
removed.

Drain/fill plugs

Remove Cover Tube or Remove Side


Hub Sealing Cap. Handwheel (If fitted)
(If fitted)
Locate and remove the fixing
The top or side handwheel screws locating the side
assembly should be fitted with handwheel hub assembly to the
a Cover Tube or Sealing Cap gearcase
to help prevent ingress of
moisture to the centre column Check that the condition of the
area. ‘O’ Ring and the sealing face is
satisfactory.
Renew if necessary.

Retain the assembly for refitting


to the new Gearcase.
Publication 002-047-00 issue 11/12
Module 1B Centre Column
IQ, IQS, IQML 10, 12, 18, 20, 25, 35 Only
Publication 002-047-00 issue 06/13

Remove Motor Stator Disconnect Torque


Transducer
Before removing motor stator
cover mark its position relative Using an Allen Wrench remove
to the top of the gearcase. the 2 screws securing the plastic
mounting bracket to the torque
transducer thrust plate.

Remove and retain the four cap Disconnect the loom connected
head screws, slide the stator off to the torque transducer.
the gearcase.

Be careful not to damage Explosionproof Units


Motor and Torque Transducer only
wiring during removal. (CENELEC/FM/CSA)
In explosionproof units there is a
black plastic cable retainer
clipped onto the thrust retaining
plate. This must be retained for
refitting.

Do not mislay the coil spring at Explosion Proof Units Only.


the outboard end of the rotor
shaft. Retain for refitting.
Explosion-proof wiring looms
are fitted with a steel transfer
bush, this is a certified flame
path and must not be scored or
damaged in any way.

Motor Rotor Remove Thrust Plate


Using an allen key (hex wrench) Remove the 3 fixings locating the
and a hex socket remove and thrust plate to the gearcase. And
retain the bolt and nut securing remove plate
the rotor shaft to the worm
shaft, slide the rotor shaft off
and retain in a safe place for
refitting.
Publication 002-047-00 issue 11/12
Module 1B Centre Column All mechanical sizes
IQ40, 70, 90, 91, 95 Only
Publication 002-047-00 issue 06/13

Remove Motor Stator Slide rotor of shaft and retain all


components for refitting.
WARNING
It is advisable to support the WT Units Only
weight of the motor as it
could weigh up to 70Kg Remove the Motor and Torque
(154lbs). Transducer wiring loom and
retain for refitting.

Before removing motor stator


mark its position relative to the
gearcase.
Explosionproof Units
only
(CENELEC/FM/CSA)
Remove and retain the four cap
head screws, slide the stator In explosionproof units there is
out of the gearcase onto the a black plastic cable retainer
work surface. clipped onto the thrust retaining
plate. This must be retained for
refitting.

Be careful not to damage Remove the 6 fixings locating


Motor and Torque Transducer the thrust plate to the gearcase
wiring during removal. to allow removal of the Motor
and Torque transducer wiring
loom and retain for refitting.

Do not mislay the coil spring at Explosion Proof Units Only.


the outboard end of the rotor
shaft. Retain for refitting. Explosion-proof wiring looms
are fitted with a steel transfer
bush, this is a certified flame
path and must not be scored
or damaged in any way.

Remove Thrust Ring

Undo 6 hex head bolts and


remove thrust ring.

Motor Rotor

Using a 36mm wrench remove


hex nut on end of rotor shaft.
Now remove locking washers
and taper coupling.

Note
Carefully remove drive key from
end of rotor shaft.
Publication 002-047-00 issue 11/12
Module 1B Centre Column All mechanical sizes
Publication 002-047-00 issue 06/13

Remove Torque
Transducer and Worm Remove Centre Column
Shaft Assembly

IQ Sizes 10, 12, 18, 20, IQ Sizes 10, 12, 18 Only


25, 35 Only Locate and remove 2 fixing
screws holding centre column
Holding end of motor shaft base plate into gearcase.
withdraw torque transducer,
and bronze bush.

The torque transducer and


bronze bush can now be Withdraw centre column
removed from the worm shaft. assembly from gearcase.

Retain in safe place for refitting. Ensure the clutch lifting cam is
disengaged or this will prevent
Do not dismantle torque the assembly from withdrawing.
transducer assembly.

IQ Sizes 40, 70, 90, 91, IQ Sizes 20, 25, 40, 70,
95 Only 90, 91, 95 Only

Holding end of motor shaft Locate and remove 4 fixing


withdraw the shaft and torque screws holding centre column
transducer assembly. base plate into gearcase.

Remove the Torque


Transducer from the
Wormshaft

First remove the 10 mm


diameter drive pin from the
worm shaft.

To remove pin secure shaft in


soft jaw vice and drive out with Ensure the clutch lifting cam is
parallel pin punch. disengaged or this will prevent
the assembly from withdrawing.
Unscrew the hex locking screw,
this will allow the torque Withdraw centre column
transducer and bearing to be assembly from gearcase.
removed and retained in safe
place for refitting. It is advisable to use a lifting
device for safe removal of this
Do not dismantle torque module.
transducer assembly.
Publication 002-047-00 issue 11/12
Module 1B Centre Column All mechanical sizes
Publication 002-047-00 issue 06/13

The lower seal can now be


removed with a suitable tool. Using 6mm Allen key (hex head)
locate and tighten 2 screws
holding cast plate into gearbox.

Reassembly of IQ Sizes 20, 25, 40, 70,


Actuator using new 90, 91 Only
components as
supplied in Module 1B Lightly grease the lower end of
centre column before fitting into
gearcase. Locate it through base
To aid reassembly and prevent seal and push into gearcase until
damage to new seals and cast plate sits on the mounting
bearings, assembly tools can face, only hand force should be
be purchased via your local necessary.
agent or direct from Rotork.

It is advisable to use a lifting


device for safe fitting of this
module.
Fit Lower Seal

Press lower seal into the Using 6mm Allen key (hex head)
gearcase from the inside, locate and tighten screws hold-
ensure seal and castings are ing cast plate into gearbox.
clean and greased and that the
lips are positioned facing
towards the inside of the
gearcase.

Refit Centre Column


Assembly

IQ Sizes 10, 12, 18 Only

Lightly grease the lower end of


centre column before fitting into
gearcase. Locate it through
base seal and push into
gearcase until cast plate sits on
the mounting face, only hand
force should be necessary.
Publication 002-047-00 issue 11/12
Module 1B Centre Column All mechanical sizes
Publication 002-047-00 issue 06/13

Refit Torque
Transducer and Worm
Shaft

IQ Sizes 10, 12, 18, 20,


25, 35 Only
The torque transducer and
bronze bush can now be fitted
from the new worm shaft.

Holding end of motor shaft refit


torque transducer, and bronze
bush.

NOTE

Locate the torque transducer


onto the dowel pin in the
gearcase. Only a light pressure
on the wormshaft will be
needed to locate the complete
assembly.

IQ Sizes 40, 70, 90, 91,


95 Only

The torque transducer, bearing


and Hex locking nut can now be
fitted from the new worm shaft.

Fit the 10 mm diameter drive


pin into the worm shaft.

To fit pin secure shaft in a soft


jaw vice and drive into position
with parallel pin punch.

Holding end of motor shaft refit


torque transducer and bronze
bush.

NOTE
Locate the torque transducer
onto the dowel pin in the
gearcase. Only a light pressure
on the wormshaft will be
needed to locate the complete
assembly.
Publication 002-047-00 issue 11/12
Module 1B Centre Column
IQ, IQS, IQM, IQML 10, 12, 18, 20, 25 & 35 Only
Publication 002-047-00 issue 06/13

Refit Motor
Fit coil spring onto outboard end
Feed the motor cables through of rotor shaft.
into the electronics
compartment.

Explosionproof Units
Only
(CENELEC/FM/CSA) Fit Motor Stator to
Remove the 3 fixings locating Gearcase
the thrust plate to the gearcase,
this will allow the steel transfer
bush and motor loom to be Before fitting motor ensure the
fitted. Refit the thrust plate. spigotted joint is clean and
lightly greased and that the ’O’
Explosion-proof wiring looms ring seal is serviceable.
are fitted with a steel transfer
bush, this is a certified flame
path and must not be scored
or damaged in any way.
WT Only
Explosionproof Units
Only Slide stator over rotor shaft, do
not damage the windings, feed
The black plastic cable retainer the motor cables into the
can now be clicked into position electrical compartment.
on the flange, ensure that the
cut-out aligns with the motor
cable.

Explosionproof Only
Reconnect the torque
transducer loom . Using an On these units the motor loom
Allen key wrench refit the remains in the motor
plastic mounting bracket onto compartment, to prevent it being
the transducer thrust plate. damaged it must be positioned
correctly in its plastic retainer as
follows:-
Position the stator onto the rotor
shaft, do not damage the
windings, whilst rotating the
stator anti-clockwise feed the
cables into the plastic retainer.
Ensure that the cables are
correctly positioned before
finally bolting stator casting onto
the gearbox. Screws to be
tightened to 16.5Nm (12lb/ft).
Fit Motor Rotor

Slide the rotor shaft onto the


end of the wormshaft, align the
bolt hole and fit shouldered bolt
and nyloc nut, tighten to 6.8Nm.
Publication 002-047-00 issue 11/12
Module 1B Centre Column
IQ 40, 70, 90, 91 & 95 Only
Publication 002-047-00 issue 06/13

Refit Motor Fit coil spring onto outboard end


of rotor shaft.
Feed the motor cables through
into the electronics
compartment.

Explosionproof Units
Only
(CENELEC/FM/CSA)
Remove the 6 fixings locating
the thrust plate to the gearcase,
this will allow the steel transfer
bush and motor loom to be
fitted. Refit the thrust plate.
Fit Motor Stator to
Explosion-proof wiring looms Gearcase
are fitted with a steel transfer
bush, this is a certified flame Before fitting motor ensure the
path and must not be scored spigotted joint is clean and
or damaged in any way. lightly greased and that the ’O’
ring seal is serviceable.
Explosionproof Units
Only
The black plastic cable retainer
can now be clicked into position
on the flange, ensure that the
cut-out aligns with the motor
cable.

WT Only

Reconnect the torque Slide stator over rotor shaft, do


transducer loom . Using an not damage the windings, feed
Allen key wrench refit the the motor cables into the
plastic mounting bracket onto electrical compartment.
the transducer thrust plate.
Explosionproof Only
On these units the motor loom
remains in the motor
compartment, to prevent it being
damaged it must be positioned
correctly in its plastic retainer as
follows:-
Fit Motor Rotor Position the stator onto the rotor
shaft, do not damage the
Slide the original rotor onto the windings, whilst rotating the
wormshaft, ensure the slot on stator anti-clockwise feed the
the in-board end engages with cables into the plastic retainer.
the locating pin. Ensure that the cables are
correctly positioned before
The components are fitted to finally bolting stator casting onto
the wormshaft in the following the gearbox. Screws to be
order:- tightened to 16.5Nm (12lb/ft).
Rotor
Key
Cone
Locking Washers
Lock Nut
Coil Spring.
Publication 002-047-00 issue 11/12
Module 1B Centre Column All mechanical sizes
Publication 002-047-00 issue 06/13

Fill Gearbox With Oil

Before fitting hand drive fill


gearcase with fresh oil through
the hand drive aperture, ensure
all oil drain plugs are sealed,
that the sliding clutch coupling
is down in the drive position and
bring the oil level up to the top
of the clutch but no higher.

Oil Capacities
IQ sizes Litres US Pints
10,12,18 0.5 1
20,25 1 2.1
35 1.5 3.2
40,70,90,91,95 3 6.3

Refit Top Handwheel

Check the condition of the ‘O’


ring is serviceable. And sealing
face is satisfactory.

Carefully refit handwheel


assembly ensuring ‘O’ ring is in
position .

Tighten down fixings with 6mm


Allen (hex wrench).
Publication 002-047-00 issue 11/12
Module 1B Centre Column All mechanical sizes
Publication 002-047-00 issue 06/13

Refit side handwheel Group ’B’ Bases and


(if fitted) Bushes
Check the condition of the ‘O’ Using the correct size circlip
ring is serviceable and sealing pliers open the circlip and
face is satisfactory. relocate the drive bush onto the
centre column ensuring the clip
Carefully refit side handwheel is located in the slot.
assembly ensuring ‘O’ ring is in
position .

Tighten down fixings with 6mm


Allen key (hex wrench)

Refit Cover Tube or


Hub sealing Cap Refit flange adaptor onto
gearcase and secure hex bolts.
The top or side handwheel
should be fitted with a cover
Tube or Sealing Cap to prevent
ingress of moisture to the
centre column area.

Torque values fitting bases


Ensure the ’O’ ring is in position
and serviceable then refit cover
tube or cap. Locate screws and
tighten using Allen key ( hex
wrench)

Refitting Drive Bush

Group ‘A’ Bases and


Drive Bushes. Refit Actuator to Valve
(Types A,Z3) or Gearbox.
If the actuator was originally
removed from the valve
together with its base and drive
coupling then these must be
refitted onto the gearcase.

Carefully align the centre


column drive dogs into drive
coupling and tighten fixings.
Module 1B Centre Column All mechanical sizes

Publication 002-047-00 issue 06/13

Replace battery
Disconnect the existing
battery and using the strap
Whilst the actuator is down for
provided pull out of its plastic
maintenance it is recommended
holder.
that its battery be changed.
The battery as fitted by Rotork
Fit new battery into strap and
is generally a PP3 9 volt
push into its holder,
Ultralife Lithium cell.
reconnect.
For Hazardous area certified
Refit and tighten threaded
units ONLY approved battery
plug after lightly greasing
types must be used.
thread and checking sealing
‘O’ ring is serviceable.
See Below for Approved Battery
Types

BATTERY TYPES

For European hazardous area certified actuators (ATEX / IEC Ex) use a Recommission the actuator
lithium manganese dioxide battery as stated in Table 1 BELOW. using Publication
Pub 002-039-00 and the
For FM and CSA certified enclosures use an Ultralife U9VL lithium Rotork Bluetooth Setting Tool.
manganese dioxide battery. Equivalent, UL recognised, batteries may
be used.

For watertight (WT) actuator enclosures Rotork recommend a lithium


manganese dioxide battery, however any equivalent 9V battery may be
used.

If in doubt regarding the correct battery type, contact Rotork.

Table 1

Enclosure Type Battery Type Detail


ATEX/IEC Ex Ultralife PP3 U9VL or
Standard Temp Types U9VL-J-P

ATEX/IEC Ex Rotork Part Numbers 95-462 or


Low/High Temp 95-614

The battery is situated in its


own compartment located in the
gearcase.

Using an 8mm allen key (hex


wrench) remove the access
plug.
Workshop and Spare Parts Manual
IQ Mk 3 Range Actuators
Module 1B/1 All mechanical sizes.
Publication 002-047-00 issue 06/13

Module 1B/1 consists of

Clutch ring
Spring
O Ring

Module 1B/1 Spring and Sliding Coupling

Full details from the actuator name plate must be given when enquiring about or ordering spare parts
Publication 002-047-00 issue 11/12
Module 1B/1 Spring and /Sliding coupling All mechanical sizes
Publication 002-047-00 issue 06/13

WARNING Remove Top Handwheel


(If fitted)
Before dismantling the
Locate and remove the fixing
actuator, isolate and screws locating the handwheel
disconnect the hub assembly to the gearcase.
incoming supply to
actuator.

Oil Plugs - Drain Oil Check that the condition of the


‘O’ Ring and the sealing face is
To drain the oil, remove one of satisfactory.
the two plugs situated in the Renew if necessary.
gearcase.
Retain the assembly for refitting
to the gearcase.
The oil may be drained from
the gearcase after the top or
side hand wheel assembly is
removed.

Remove Side
Handwheel (If fitted)
Remove Cover Tube or
Hub Sealing Cap. Locate and remove the fixing
(If fitted) screws locating the side
handwheel hub assembly to the
The top or side handwheel gearcase
assembly should be fitted with
a Cover Tube or Sealing Cap Check that the condition of the
to help prevent ingress of ‘O’ Ring and the sealing face is
moisture to the centre column satisfactory.
area. Renew if necessary.

Retain the assembly for refitting


to Gearcase.

Top Handwheel
Assembly To Remove Clutch
Spring
Locate and remove the 3 fixing
screws locating the Cover Locate the ’O’ ring on top of the
Tube or Blanking Cap to the centre column, press down on
handwheel assembly. the steel washer beneath the
`O’ ring and roll the `O’ ring up
the centre column.

Take great care when


releasing the spring.
Publication 002-047-00 issue 11/12
Module 1B/1 Spring and /Sliding coupling All mechanical sizes
Publication 002-047-00 issue 06/13

Remove clutch spring, Refit Clutch Ring


steel washer and `O’
ring. Sizes 20, 25, 35, 40, 70,
90, 91,95 Only
Lift the spring steel washer and
`o’ ring clear of the centre Before clutch ring is fitted
column. ensure the clutch lifting yoke is
in the correct position located
on its pivot pin.

Remove Clutch Ring Slide clutch ring over centre


column ensuring splines are
Lift the clutch ring clear of the engaged.
centre column. Note the
original position for fitting
replacement.

Refit clutch spring,


steel washer and `O’
ring.

Place the coil spring, steel


washer with its chamfer
To make the job safer, a clutch uppermost onto the centre
spring compression tool should column in that order.
be used to compress the spring
and allow the `o’ ring to be To make the job safer, a clutch
released. spring compression tool should
be used to compress the spring
and allow the `o’ ring to be
fitted.

Fill Gearbox With Oil

Before fitting hand drive fill


gearcase with fresh oil through
the hand drive aperture, ensure
Reassembly of actuator all oil drain plugs are sealed,
that the sliding clutch coupling is
using new components down in the drive position and
as supplied in Module bring the oil level up to the top
1B/1 of the clutch but no higher.

Oil Capacities
IQ sizes Litres US Pints
10,12,18 0.5 1
20,25 1 2.1
35 1.5 3.2
40,70,90,91,95 3 6.3
Publication 002-047-00 issue 11/12

Module 1B/1 Spring and /Sliding coupling All


Publication 002-047-00 issue 06/13

Refit Top Handwheel Refit Cover Tube or


Check the condition of the ‘O’
Hub sealing Cap
ring is serviceable. And sealing
face is satisfactory. The top or side handwheel
should be fitted with a cover
Tube or Sealing Cap to prevent
ingress of moisture to the centre
column area.

Ensure the ’O’ ring is in position


Carefully refit handwheel and serviceable then refit cover
assembly ensuring ‘O’ ring is in tube or cap. Locate screws and
position .

Tighten down fixings with 6mm


Allen (hex wrench).

Refit side handwheel


(if fitted)

Check the condition of the ‘O’


ring is serviceable. And sealing
face is satisfactory.

Carefully refit side handwheel


assembly ensuring ‘O’ ring is in
position .

Tighten down fixings with 6mm


Allen key (hex wrench)

tighten using Allen key ( hex


wrench)
Workshop and Spare Parts Manual
IQ Mk 3 Range Actuators
Module 1C Encoder Drive Shaft Assembly All mechanical sizes.
Publication 002-047-00 issue 06/13

Module 1C
Encoder Drive shaft, fixings and seals.

Module 1C Encoder Drive Shaft Assembly

Full details from the actuator name plate must be given when enquiring about or ordering spare parts
Module 1C Encoder Drive Shaft Assembly All mechanical sizes.

Publication 002-047-00 issue 06/13

The actuator may remain in situ Locate the two retaining clips
on the valve if required when on either side of the chassis
changing out this module. mounts.

WARNING Depress the clips and carefully


First isolate the remove the Logic Control PCB
together with its mounting ring
actuator from all from the two chassis retaining
electrical supplies. legs.
Position the two legs to the
sides to aid removal.
Note its position relative to the
gearcase to ensure correct
Remove Electronics alignment when refitting
Cover replacement module.

Using a 6mm allen key (hex


wrench) remove the four cap Move the two chassis legs
head screws securing the outboard towards the casting.
electronics cover. There is no need to remove
If necessary fit two of these them at this stage.
screws into the threaded holes
in the cover to jack it out. Take note of cable routeing so
Care must be taken in that it can be refitted in exactly
removing this cover as there is the same position on
an electrical cable between it reassembly.
and the Logic Control PCB.

Disconnect the plug and Disconnect all remaining cables


socket. Retain this cover and from the Logic Control PCB and
‘O’ ring seal for fitting to the any option cards fitted to it, note
new Gearcase Assembly. their positions for ease of
reassembly.

Retain for fitting to the new


Gearcase Assembly.

Push back the two chassis


legs .

The legs may be removed from


the chassis at this stage.
Remove Main PCB
Disconnect the ribbon cable
located on the right hand side
of chassis from the Logic
Control PCB to the power
supply module.

Disconnect Power
Disconnect any cables and
Module (3 Phase)
looms connected to the top of
the Logic Control PCB and any Disconnect all cables going onto
Option cards if fitted. the contactors taking note of
their positions:-
3 Phase Power marked 1-2-3.
3 Phase Motor marked U-V-W.
Coils marked C1-C2-CC.
Module 1C Encoder Drive Shaft Assembly All mechanical sizes.

Publication 002-047-00 issue 06/13

Disconnect Power Lift the module carefully away


from the gearcase.
Module (Single
Phase) Note: that there are cables
connected to the rear of the
Disconnect all cables going assembly.
from the terminal
compartment to the
capacitors and solid state Disconnect any looms connected
start relay taking note of to SKT 2 & SKT 4
their positions.

Remove Power
Remove the loom connected to
Module the Encoder.
Before removing power
module take note of the
cable routeing so that it can
be replicated when fitting
replacement.

Using a 5mm Allen wrench Using a 5 mm Allen wrench


locate and remove the five locate and remove two encoder
power module fixing screws. fixing screws.
The encoder can now be
withdrawn from the gearcase.

Note WARNING

IQ Sizes 40 to 95 Before removing the


Encoder drive shaft the
The contactor size is larger
however the removal gearbox oil must first be
procedure is the same. drained.
Module 1C Encoder Drive Shaft Assembly All mechanical sizes.

Publication 002-047-00 issue 06/13

Drain Oil Check that the condition of the


‘O’ Ring and the sealing face is
To drain the oil, remove the two satisfactory.
plugs situated in the gearcase. Renew if necessary.

The top or side hand wheel


assembly can also be removed
to facilitate draining and refilling
of the oil.

Remove Cover Tube or Remove Top Handwheel


Hub Sealing Cap Assembly (if fitted)
(if fitted)
Remove the fixing screws
The top or side handwheel locating the side handwheel hub
assembly should be fitted with assembly to the gearcase.
a Cover Tube or Sealing Cap to
help prevent ingress of moisture
To the centre column area.

Top Handwheel
Assembly Using suitable pliers remove the
circlip securing the encoder drive
shaft.
Locate and remove the 3 fixing
screws locating the cover tube
or blanking cap to the gearcase.

Remove Top Handwheel


Holding the end of the shaft
Assembly (if fitted) withdraw the shaft , oil seal and
bronze bush from the gearcase.
Remove the fixing screws
locating the handwheel hub
assembly to the gearcase.
Module 1C Encoder Drive Shaft Assembly All mechanical
Publication sizes.
002-047-00 issue 11/12

Publication 002-047-00 issue 06/13

Lightly grease the replacement Carefully refit Top or Side


encoder shaft , bronze bush handwheel assembly ensuring
and oil seal before assembly. ‘O’ ring is in position .

Slide the components in to Tighten down fixings with 6mm


place taking care not to damage Allen (hex wrench).
the oil seal.

Refit Encoder
Assembly

Secure the Encoder shaft It is important to align


assembly with a new circlip. the encoder drive shaft
with the input socket.

Refit Drain Plugs.

Fill Gearbox With Oil Refit the Encoder loom to the


socket on top of the assembly.
Before fitting hand drive fill
gearcase with fresh oil through
the hand drive aperture, ensure Locate the Encoder in position
all oil drain plugs are sealed, and using a 5 mm Allen wrench
that the sliding clutch coupling tighten the two fixings to 0.5Nm.
is down in the drive position and
bring the oil level up to the top
of the clutch but no higher.

Oil Capacities
IQ sizes Litres US Pints
10,12,18 0.5 1
20,25 1 2.1
35 1.5 3.2
40,70,90,91,95 3 6.3 Refit Power Module

Refit Top Handwheel Before securing the power


module into position locate the
Check the condition of the ‘O’ cables into their correct area.
ring is serviceable. And sealing
face is satisfactory. Lift the module carefully into
position in the gearcase.

Note: that there are cables


connected to the rear of the
assembly.
Module 1C Encoder Drive Shaft Assembly All mechanical
Publication sizes.
002-047-00 issue 11/12

Publication 002-047-00 issue 06/13

Using a 5mm Allen wrench


Reonnect all remaining cables
locate and tighten screws
to the Logic Control PCB and
ensuring no cables are
any option cards fitted to it, note
trapped , tighten down fixing
their original positions.
screws to 11Nm (8lb/ft).

Refit 3 Phase Power


Module

Note

IQ Sizes 40 to 95
Take care to route the cables in
The contactor size is larger
their original positions.
however the replacement
procedure is the same.
Locate the two retaining clips
on either side of the chassis
Reconnect motor cables
mounting legs.
marked U, V, W onto marked
terminals on right hand
Carefully relocate the logic
contactor. Connect 3 phase
control PCB into position and
supply cables marked 2, 3, 1 to
snap the retaining clips into
marked terminal on left hand
position.
contactor.

Reconnect the ribbon cable


Reconnect Power located on the right hand side of
Module (Single Phase) the chassis from the logic
control PCB to the power
Reconnect all cables going from module.
the terminal compartment to the
capacitors and solid state start
relay taking note of their
original positions.

Refit Electronics cover

First check the spigotted joint is


Reconnect Main PCB clean ,lightly greased and the
‘O’ ring seal is serviceable.
If legs have been removed
relocate onto chassis plate. Connect the cable loom from
Close mounting legs back to HMI PCB to logic control PCB.
centre position.
Refit cover taking care not to
trap any cables.

Using a 6mm Allen key (hex


wrench) tighten 4 screws to
16.5Nm (12lb/ft).
Module 1C Encoder Drive Shaft Assembly All mechanical sizes.

Publication 002-047-00 issue 06/13

Replace battery
Disconnect the existing battery and using the strap
provided pull out of its plastic holder.
Whilst the actuator is down for
maintenance it is recommended
Fit new battery into strap and push into its holder,
that its battery be changed.
reconnect.
The battery as fitted by Rotork
is generally a PP3 9 volt
Refit and tighten threaded plug after lightly greasing
Ultralife Lithium cell.
thread and checking sealing ‘O’ ring is serviceable.
For Hazardous area certified
units ONLY approved battery
types must be used.

See Below for Approved Battery


Types

BATTERY TYPES

For European hazardous area certified actuators (ATEX / IEC Ex) use a
lithium manganese dioxide battery as stated in Table 1 BELOW.

For FM and CSA certified enclosures use an Ultralife U9VL lithium


manganese dioxide battery. Equivalent, UL recognised, batteries may
be used.

For watertight (WT) actuator enclosures Rotork recommend a lithium


manganese dioxide battery, however any equivalent 9V battery may be
used.

If in doubt regarding the correct battery type, contact Rotork.

Table 1

Enclosure Type Battery Type Detail


ATEX/IEC Ex Ultralife PP3 U9VL or
Standard Temp Types U9VL-J-P Recommission the actuator using Publication Pub 002-039-00 and
the Rotork Bluetooth Setting Tool.
ATEX/IEC Ex Rotork Part Numbers 95-462 or
Low/High Temp 95-614

The battery is situated in its


own compartment located in the
gearcase.

Using an 8mm allen key (hex


wrench) remove the access
plug.
Workshop and Spare Parts Manual
IQ Mk 3 Range Actuators
Module 1D Encoder Assembly All mechanical sizes.
Publication 002-047-00 issue 06/13

Module 1D
Encoder Assembly , fixings and wiring loom.

Module 1D Encoder Assembly

Full details from the actuator name plate must be given when enquiring about or ordering spare parts
Module 1D Encoder Assembly All mechanical sizes

Publication 002-047-00 issue 06/13

The actuator may remain in situ Locate the two retaining clips
on the valve if required when on either side of the chassis
changing out this module. mounts.

WARNING Depress the clips and carefully


First isolate the actuator remove the Logic Control PCB
from all electrical supplies. together with its mounting ring
from the two chassis retaining
legs.
Position the two legs to the
sides to aid removal.
Note its position relative to the
Remove Electronics gearcase to ensure correct
Cover alignment when refitting
replacement module.
Using a 6mm allen key (hex
wrench) remove the four cap Move the two chassis legs
head screws securing the outboard towards the casting.
electronics cover. There is no need to remove
If necessary fit two of these them at this stage.
screws into the threaded holes
in the cover to jack it out. Take note of cable routeing so
Care must be taken in that it can be refitted in exactly
removing this cover as there is the same position on
an electrical cable between it reassembly.
and the Logic Control PCB.

Disconnect the plug and Disconnect all remaining cables


socket. Retain this cover and from the Logic Control PCB and
‘O’ ring seal for fitting to the any option cards fitted to it, note
new Gearcase Assembly. their positions for ease of
reassembly.

Retain for fitting to the new


Gearcase Assembly.

Push back the two chassis


legs .

The legs may be removed from


Remove Main PCB the chassis at this stage.

Disconnect the ribbon cable


located on the right hand side
of chassis from the Logic
Control PCB to the power
supply module.

Disconnect Power
Module (3 Phase)
Disconnect any cables and
looms connected to the top of Disconnect all cables going onto
the Logic Control PCB and any the contactors taking note of
Option cards if fitted. their positions:-
3 Phase Power marked 1-2-3.
3 Phase Motor marked U-V-W.
Coils marked C1-C2-CC.
Module 1D Encoder Assembly All mechanical sizes

Publication 002-047-00 issue 06/13

Lift the module carefully away


Disconnect Power from the gearcase.
Module (Single Note: that there are cables
Phase) connected to the rear of the
assembly.
Disconnect all cables going
from the terminal
compartment to the Disconnect any looms connected
capacitors and solid state to SKT 2 & SKT 4
start relay taking note of
their positions.

Remove Power
Remove the loom connected to
Module the Encoder.
Before removing power
module take note of the
cable routeing so that it can
be replicated when fitting
replacement.

Using a 5 mm Allen wrench


Using a 5mm Allen wrench locate and remove two encoder
locate and remove the five fixing screws.
power module fixing screws. The encoder can now be
withdrawn from the gearcase.

Note
Fit Replacement Encoder
IQ Sizes 40 to 95 Assembly
The contactor size is larger
however the removal
procedure is the same. It is important to align the
encoder drive shaft with
the input socket.
Publication 002-047-00 issue 11/12
Module 1D Encoder Assembly All mechanical sizes
Publication 002-047-00 issue 06/13

Using a 5 mm Allen wrench Using a 5mm Allen wrench


screw tighten the two fixings d locate and tighten screws
to 0.5Nm. ensuring no cables are trapped ,
tighten down fixing screws to
Reconnect the loom onto the 11Nm (8lb/ft).
encoder socket.

The electronics module Note


previously removed from the
original gearcase can now be IQ Sizes 40 to 95
refitted, first confirm that all
cables from the terminal bung The contactor size is larger
and motor loom have been however the replacement
pulled through into the procedure is the same.
electronics compartment.

Refit Power Module Reconnect motor cables


marked U, V, W onto marked
Before securing the power terminals on right hand
module into position locate the contactor. Connect 3 phase
cables into their correct area. supply cables marked 2, 3, 1 to
marked terminal on left hand
Lift the module carefully into contactor.
position in the gearcase.

Note: that there are cables


connected to the rear of the
assembly.

Reconnect Power
Module (Single Phase)
Reconnect all cables going from
the terminal compartment to the
capacitors and solid state start
relay taking note of their
original positions.

Reconnect Main PCB

If legs have been removed


relocate onto chassis plate.
Close mounting legs back to
centre position.
Publication 002-047-00 issue 11/12
Module 1D Encoder Assembly All mechanical sizes
Publication 002-047-00 issue 06/13

Reonnect all remaining cables Using a 6mm Allen key (hex


to the Logic Control PCB and wrench) tighten 4 screws to
any option cards fitted to it, note 16.5Nm (12lb/ft).
their original positions.

Take care to route the cables in


their original positions.

Locate the two retaining clips


on either side of the chassis
mounting legs.

Carefully relocate the logic


control PCB into position and
snap the retaining clips into
position.

Reconnect the ribbon cable


located on the right hand side of
the chassis from the logic
control PCB to the power
module.

Refit Electronics cover

First check the spigotted joint is


clean ,lightly greased and the
‘O’ ring seal is serviceable.

Connect the cable loom from


HMI PCB to logic control PBC.

Refit cover taking care not to


trap any cables.
Module 1D Encoder Assembly

Publication 002-047-00 issue 06/13

Replace battery
Disconnect the existing battery and using the strap
provided pull out of its plastic holder.
Whilst the actuator is down for
maintenance it is recommended
Fit new battery into strap and push into its holder,
that its battery be changed.
reconnect.
The battery as fitted by Rotork
is generally a PP3 9 volt
Refit and tighten threaded plug after lightly greasing
Ultralife Lithium cell.
thread and checking sealing ‘O’ ring is serviceable.
For Hazardous area certified
units ONLY approved battery
types must be used.

See Below for Approved Battery


Types

BATTERY TYPES

For European hazardous area certified actuators (ATEX / IEC Ex) use a
lithium manganese dioxide battery as stated in Table 1 BELOW.

For FM and CSA certified enclosures use an Ultralife U9VL lithium


manganese dioxide battery. Equivalent, UL recognised, batteries may
be used.

For watertight (WT) actuator enclosures Rotork recommend a lithium


manganese dioxide battery, however any equivalent 9V battery may be
used.

If in doubt regarding the correct battery type, contact Rotork.

Table 1

Enclosure Type Battery Type Detail


ATEX/IEC Ex Ultralife PP3 U9VL or
Standard Temp Types U9VL-J-P Recommission the actuator using Publication Pub 002-039-00 and
the Rotork Bluetooth Setting Tool.
ATEX/IEC Ex Rotork Part Numbers 95-462 or
Low/High Temp 95-614

The battery is situated in its


own compartment located in the
gearcase.

Using an 8mm allen key (hex


wrench) remove the access
plug.
Workshop and Spare Parts Manual
IQ Mk 3 Range Actuators
Module 1E Wormshaft Maintenance Kit
All mechanical sizes. Publication 002-047-00 issue 06/13

Module 1E consists of the following


components:-

Wormshaft Bearings (2)


Bronze bush with seals
Screws (3)
‘O’ rings
Drive pin and lock nut

To gain access to these components in the


gearcase please refer to instructions for
module 1B.

Module 1E Typical components,.


Note, Components will vary in size according to actuator size.

Full details from the actuator name plate must be given when enquiring about or ordering spare parts
Workshop and Spare Parts Manual
IQ Mk 3 Range Actuators
Module 1F Gearcase Maintenance Kit
All mechanical sizes. Publication 002-047-00 issue 06/13

Module 1F consists of the following


components:-

Bronze bush with seals


Screw
‘O’ rings
Seals
circlip

To gain access to these components in the


gearcase please refer to instructions for
module 1B,1C,1G.

Module 1E Typical components,.


Note, Components will vary in size according to actuator size.

Full details from the actuator name plate must be given when enquiring about or ordering spare parts
Workshop and Spare Parts Manual
IQ Mk 3 Range Actuators
Module 1G Hand Auto Mechanism All mechanical sizes.
Publication 002-047-00 issue 06/13

Module 1G Hand / Auto Mechanism consists


of :-

Hand / Auto Lever


Cam
Spring
Stop Screw
O Rings

Also on sizes: 40, 70,90,91 and 95


Drive Key

Module 1G components
sizes 10,12,18,20,35

Module 1G components
sizes 40,70,90,91,95

Full details from the actuator name plate must be given when enquiring about or ordering spare parts
Publication 002-047-00 issue 11/12
Module 1G Hand Auto Mechanism All mechanical sizes.
Publication 002-047-00 issue 06/13

It is not necessary to Removal of Actuator


remove the actuator from Valve Gearbox
from the valve or Take weight of the actuator on
gearbox to replace the the sling before removing the
hand auto lever. Pic 26 actuator to gearbox fixings.
Actuator should slide off
gearbox input shaft, ensure
Removing Actuator sling is holding the weight of the
from Valve if actuator at all times.
applicable.
WARNING
Before dismantling the actuator
isolate and disconnect incoming
electrical supply to actuator.
Remove and retain any
adaptors or reducers from the
threaded cable entries. Remove Drive Bush
Actuator sizes 12-95 can be
removed from their bases
leaving this to maintain the IQ sizes 10 to 95
valve position. In this case the Pic 27
base must be protected from Group ‘A’ Bases and
the environment.
Drive Bushes
(Types A, Z3 )
Alternatively, the actuator and
base can be removed as one To remove the thrust base from
piece. the actuator first remove the
stainless steel securing bolts,
Remove Actuator from retain these for refitting later.
Valve or Gearbox

WARNING Actuator Weights

ONLY PERSONS COMPETENT 10,12,18 = 31Kgs / 68lbs


BY VIRTUE OF THEIR TRAINING
AND EXPERIENCE SHOULD BE
20,25 = 54Kgs / 119lbs
ALLOWED TO REMOVE
ACTUATOR FROM THE VALVE
OR GEARBOX. 35 = 75Kgs / 165lbs

40, 70 = 145Kgs / 320lbs


AS THE ACTUATOR MAY BE
INSTALLED AT ANY ANGLE, 90, 95 = 160Kgs / 353lbs
CORRECT SLINGING OF THIS
UNIT MUST BE JUDGED IN
EACH INDIVIDUAL CASE. 91 = 150Kgs / 331lbs

Actuator Direct
Mounted onto Rising
Stem Valves
WARNING
Ensure pressure is removed Pic 75
from pipeline, move valve
‘open’ a short distance to
eliminate any locked in
pressure, close the valve fully. Size 10,12,25 (F10 , FA10) Sizes 40 to 95 (F25 & F30)
Take the weight of the actuator A Type Thrust Base A Type Thrust Base
on the sling before removing
the actuator to valve fixings,
wind the handwheel in the
‘close’ direction when actuator
will move up the valve stem,
ensure sling is holding the
weight at all times.
Publication 002-047-00 issue 11/12
Module 1G Hand Auto Mechanism All mechanical sizes.
Publication 002-047-00 issue 06/13

IQ sizes 10 to 95 Top Handwheel


Assembly
Remove ‘B’ Type Base
Locate and remove the 3 fixing
Remove the Flange to Actuator screws locating the Cover Tube
Gearcase fixing bolts and lift off or Blanking Cap to the
the flange. handwheel assembly.

Remove Top Handwheel


Using the correct size circlip (If fitted)
pliers open the circlip and
remove, coupling can now be Locate and remove the fixing
knocked out from the screws locating the handwheel
handwheel end. hub assembly to the gearcase.

Oil Plugs - Drain Oil


Check that the condition of the
To drain the oil, remove one of ‘O’ Ring and the sealing face is
the two plugs situated in the satisfactory.
gearcase. Renew if necessary.
The oil may be drained from the Retain the assembly for refitting
gearcase after the top or side to the new Gearcase.
hand wheel assembly is
removed.

Remove Cover Tube or


Remove Side
Hub Sealing Cap.
(If fitted) Handwheel (If fitted)

The top or side handwheel Locate and remove the fixing


assembly should be fitted with screws locating the side
a Cover Tube or Sealing Cap handwheel hub assembly to the
to help prevent ingress of gearcase
moisture to the centre column
area. Check that the condition of the
‘O’ Ring and the sealing face is
satisfactory.
Renew if necessary.

Retain the assembly for refitting


to the new Gearcase.
Publication 002-047-00 issue 11/12
Module 1G Hand Auto Mechanism All mechanical sizes
Publication 002-047-00 issue 06/13

Remove Hand Auto Remove move clutch


Lever spring, steel washer
and ‘o’ ring.
Sizes 10,12,18,20,25,35 Lift the spring steel washer and
‘o’ ring clear of the centre
Rotate Hand / Auto lever to column.
horizontal position to allow
removal of stop screw.
Locate and remove stop screw
threaded into shaft using 6 mm
hex key.

Remove clutch ring


Rotate Hand / Auto lever to
vertical position, the lever can and lifting yolk.
now be pulled out of the
gearcase.
Remove the clutch ring and
Note the position of the cam lifting yolk clear of the centre
and spring for reassembly column. Note the original
procedure. position for reassembly.

Remove the cam and spring


from the gearcase.

Sizes 40,70,90,91,95
Rotate Hand / Auto lever to
To remove Hand / Auto lever
horizontal position to allow
on sizes above IQ40 it is
removal of stop screw.
necessary to remove the
Locate and remove stop screw
clutch mechanism.
threaded into shaft using 6 mm
hex key.
To make the job safer a clutch
spring compression tool should
be used to compress the spring
to allow the ‘o’ ring to be
released.

Rotate Hand / Auto lever to


vertical position, remove key
from shaft. The lever can now
Locate the ’o’ ring on top of the
be pulled out of the gearcase.
centre column, press down on
the steel washer beneath the
Note the position of the cam
’o’ ring and roll the ’o’ ring up
and spring for reassembly
the centre column.
procedure.
Take great care when
releasing the spring
Publication 002-047-00 issue 11/12
odule 1G Hand Auto Mechanism All mechanical sizes
Publication 002-047-00 issue 06/13

When the spring and the cam


Reassemble Hand / are in the correct position push
Auto Assembly Using the lever fully into the gear
New Components. case.

Before fitting lever ensure that Rotate Hand / Auto lever to


the two ‘o’ ring seals are in horizontal position to allow
position on the shaft and that fitting of stop screw.
they are lightly greased. Tighten screw into shaft using 6
mm hex key.

Sizes 40,70,90,91,95
only
With the lever in the vertical
position insert partially into the Refit Clutch Ring
gearcase.
Before clutch ring is fitted
Slide the spring onto the shaft ensure the clutch lifting yolk is in
with the hook pointing down. the correct position located on
Engage the tail of the spring its pivot pin.
into the slot in the shaft.

With the spring in position slide Slide clutch ring over centre
the cam onto the end of the column ensuring splines are
shaft with the spring loaded engaged.
finger pointing down.
It may be necessary to rotate
the shaft slightly from side to
side to engage the cam into the
correct position.

Place the coil spring, steel


Sizes 40,70,90,91,95 washer with its chamfer
only uppermost onto the centre
column n in that order.
Rotate and position the lever to
insert the key into key slot in Press down on the steel washer
lever shaft. to compress the spring. Slide
the ’o’ ring over the centre
column and down into its grove.

To make the job safer a clutch


spring compression tool should
be used to compress the spring
to allow the ‘o’ ring to be
released.
Publication 002-047-00 issue 11/12
Module 1G Hand Auto Mechanism All mechanical sizes
Publication 002-047-00 issue 06/13

Fill Gearbox With Oil

Before fitting hand drive fill


gearcase with fresh oil through
the hand drive aperture, ensure
all oil drain plugs are sealed,
that the sliding clutch coupling
is down in the drive position and
bring the oil level up to the top
of the clutch but no higher.

Oil Capacities
IQ sizes Litres US Pints
10,12,18 0.5 1
20,25 1 2.1
35 1.5 3.2
40,70,90,91,95 3 6.3

Refit Top Handwheel

Check the condition of the ‘O’


ring is serviceable. And sealing
face is satisfactory.

Carefully refit handwheel


assembly ensuring ‘O’ ring is in
position .

Tighten down fixings with 6mm


Allen (hex wrench).
Publication 002-047-00 issue 11/12
Module 1G Hand Auto Mechanism All mechanical sizes
Publication 002-047-00 issue 06/13

Group ’B’ Bases and


Refit Side Handwheel Bushes
(if fitted)
Using the correct size circlip
Check the condition of the ‘O’ pliers open the circlip and
ring is serviceable. And sealing relocate the drive bush onto the
face is satisfactory. centre column ensuring the clip
is located in the slot.
Carefully refit side handwheel
assembly ensuring ‘O’ ring is in
position .

Tighten down fixings with 6mm


Allen key (hex wrench)

Refit Cover Tube or


Hub sealing Cap Refit flange adaptor onto
gearcase and secure hex bolts.
The top or side handwheel
should be fitted with a cover
Tube or Sealing Cap to prevent
ingress of moisture to the
centre column area.

Torque values fitting bases

Ensure the ’O’ ring is in position


and serviceable then refit cover
tube or cap. Locate screws and
tighten using Allen key ( hex
wrench)

Refitting Drive Bush

Group ‘A’ Bases and


Drive Bushes. Refit Actuator to Valve or
(Types A,Z3) Gearbox if required.
If the actuator was originally
removed from the valve
together with its base and drive
coupling then these must be
refitted onto the gearcase.

Carefully align the centre


column drive dogs into drive
coupling and tighten fixings.
Module 1G Hand Auto Mechanism All mechanical sizes

Publication 002-047-00 issue 06/13

Replace battery
Disconnect the existing battery and using the strap
provided pull out of its plastic holder.
Whilst the actuator is down for
maintenance it is recommended
Fit new battery into strap and push into its holder,
that its battery be changed.
reconnect.
The battery as fitted by Rotork
is generally a PP3 9 volt
Refit and tighten threaded plug after lightly greasing
Ultralife Lithium cell.
thread and checking sealing ‘O’ ring is serviceable.
For Hazardous area certified
units ONLY approved battery
types must be used.

See Below for Approved Battery


Types

BATTERY TYPES

For European hazardous area certified actuators (ATEX / IEC Ex) use a
lithium manganese dioxide battery as stated in Table 1 BELOW.

For FM and CSA certified enclosures use an Ultralife U9VL lithium


manganese dioxide battery. Equivalent, UL recognised, batteries may
be used.

For watertight (WT) actuator enclosures Rotork recommend a lithium


manganese dioxide battery, however any equivalent 9V battery may be
used.

If in doubt regarding the correct battery type, contact Rotork.

Table 1

Enclosure Type Battery Type Detail


ATEX/IEC Ex Ultralife PP3 U9VL or
Standard Temp Types U9VL-J-P Recommission the actuator using Publication Pub 002-039-00 and
the Rotork Bluetooth Setting Tool.
ATEX/IEC Ex Rotork Part Numbers 95-462 or
Low/High Temp 95-614

The battery is situated in its


own compartment located in the
gearcase.

Using an 8mm allen key (hex


wrench) remove the access
plug.

6
Workshop and Spare Parts Manual
IQ Mk 3 Range Actuators
Module 1G/1 Hand Auto Cam Kit All mechanical sizes.
Publication 002-047-00 issue 06/13

Module 1G/1 Hand / Auto Kit consists of :-

Cam
Spring
Stop Screw
O Rings

Also on sizes 40, 70,90,91 and 95


Drive Key

Module 1G/1 components


sizes 10,12,18,20,35

Module 1G/1 components


sizes 40,70,90,91,95

Full details from the actuator name plate must be given when enquiring about or ordering spare parts
Publication 002-047-00 issue 11/12
Module 1G/1 Hand Auto Cam Kit All mechanical sizes
Publication 002-047-00 issue 06/13

It is not necessary to Removal of Actuator


remove the actuator from Valve Gearbox
from the valve or
Take weight of the actuator on
gearbox to replace the the sling before removing the
hand auto lever. Pic 26 actuator to gearbox fixings.
Actuator should slide off
Removing Actuator gearbox input shaft, ensure
sling is holding the weight of the
from Valve if actuator at all times.
applicable.
WARNING
Before dismantling the actuator
isolate and disconnect incoming
electrical supply to actuator.
Remove and retain any
adaptors or reducers from the
threaded cable entries.
Actuator sizes 12-95 can be Remove Drive Bush
removed from their bases
leaving this to maintain the IQ sizes 10 to 95
valve position. In this case the Pic 27
base must be protected from
the environment. Group ‘A’ Bases and
Drive Bushes
Alternatively, the actuator and (Types A, Z3 )
base can be removed as one
piece. To remove the thrust base from
the actuator first remove the
stainless steel securing bolts,
Remove Actuator from retain these for refitting later.
Valve or Gearbox

WARNING Actuator Weights

ONLY PERSONS COMPETENT 10,12,18 = 31Kgs / 68lbs


BY VIRTUE OF THEIR TRAINING
AND EXPERIENCE SHOULD BE 20,25 = 54Kgs / 119lbs
ALLOWED TO REMOVE
ACTUATOR FROM THE VALVE
OR GEARBOX. 35 = 75Kgs / 165lbs

40, 70 = 145Kgs / 320lbs


AS THE ACTUATOR MAY BE
INSTALLED AT ANY ANGLE, 90, 95 = 160Kgs / 353lbs
CORRECT SLINGING OF THIS
UNIT MUST BE JUDGED IN
91 = 150Kgs / 331lbs
EACH INDIVIDUAL CASE.

Actuator Direct
Mounted onto Rising
Stem Valves
WARNING
Ensure pressure is removed
from pipeline, move valve Pic 75
‘open’ a short distance to
eliminate any locked in
pressure, close the valve fully.
Take the weight of the actuator Size 10,12,25 (F10 , FA10) Sizes 40 to 95 (F25 & F30)
on the sling before removing A Type Thrust Base A Type Thrust Base
the actuator to valve fixings,
wind the handwheel in the
‘close’ direction when actuator
will move up the valve stem,
ensure sling is holding the
weight at all times.
Publication 002-047-00 issue 11/12
Module 1G/1 Hand Auto Cam Kit All mechanical sizes
Publication 002-047-00 issue 06/13

IQ sizes 10 to 95 Top Handwheel


Assembly
Remove ‘B’ Type Base
Locate and remove the 3 fixing
Remove the Flange to Actuator screws locating the Cover Tube
Gearcase fixing bolts and lift off or Blanking Cap to the
the flange. handwheel assembly.

Remove Top Handwheel


Using the correct size circlip (If fitted)
pliers open the circlip and
remove, coupling can now be Locate and remove the fixing
knocked out from the screws locating the handwheel
handwheel end. hub assembly to the gearcase.

Oil Plugs - Drain Oil Check that the condition of the


‘O’ Ring and the sealing face is
To drain the oil, remove one of satisfactory.
the two plugs situated in the Renew if necessary.
gearcase.
Retain the assembly for refitting
The oil may be drained from to the new Gearcase.
the gearcase after the top or
side hand wheel assembly is
removed.

Remove Side
Remove Cover Tube or
Handwheel (If fitted)
Hub Sealing Cap.
(If fitted) Locate and remove the fixing
screws locating the side
The top or side handwheel handwheel hub assembly to the
assembly should be fitted with gearcase
a Cover Tube or Sealing Cap
to help prevent ingress of Check that the condition of the
moisture to the centre column ‘O’ Ring and the sealing face is
area. satisfactory.
Renew if necessary.

Retain the assembly for refitting


to the new Gearcase.
Publication 002-047-00 issue 11/12
Module 1G/1 Hand Auto Cam Kit All mechanical sizes
Publication 002-047-00 issue 06/13

Remove Hand Auto Remove move clutch


Lever spring, steel washer
and ‘O’ ring.
Sizes 10,12,18,20,25,35 Lift the spring steel washer and
‘o’ ring clear of the centre
Rotate Hand / Auto lever to column.
horizontal position to allow
removal of stop screw.
Locate and remove stop screw
threaded into shaft using 6 mm
hex key.

Remove clutch ring


Rotate Hand / Auto lever to
vertical position, the lever can and lifting yolk.
now be pulled out of the
gearcase.
Remove the clutch ring and
Note the position of the cam lifting yolk clear of the centre
and spring for reassembly column. Note the original
procedure. position for reassembly.

Remove the cam and spring


from the gearcase.

Sizes 40,70,90,91,95
Rotate Hand / Auto lever to
To remove Hand / Auto horizontal position to allow
lever on sizes above removal of stop screw.
Locate and remove stop screw
IQ40 it is necessary to threaded into shaft using 6 mm
remove the clutch hex key.
mechanism.
To make the job safer a clutch
spring compression tool should
be used to compress the spring
to allow the ‘o’ ring to be
released.

Locate the ’o’ ring on top of the Rotate Hand / Auto lever to
centre column, press down on vertical position, remove key
the steel washer beneath the from shaft. The lever can now
’o’ ring and roll the ’o’ ring up be pulled out of the gearcase.
the centre column.
Note the position of the cam
Take great care when and spring for reassembly
releasing the spring procedure.
Publication 002-047-00 issue 11/12
Module 1G/1 Hand Auto Cam Kit All mechanical sizes
Publication 002-047-00 issue 06/13

When the spring and the cam


Reassemble Hand / are in the correct position push
Auto Assembly Using the lever fully into the gear
New Components. case.

Before fitting lever ensure that Rotate Hand / Auto lever to


the two ‘o’ ring seals are in horizontal position to allow
position on the shaft and that fitting of stop screw.
they are lightly greased. Tighten screw into shaft using 6
mm hex key.

Sizes 40,70,90,91,95
With the lever in the vertical only
position insert partially into the
gearcase.
Refit Clutch Ring
Slide the spring onto the shaft
with the hook pointing down. Before clutch ring is fitted
Engage the tail of the spring ensure the clutch lifting yolk is in
into the slot in the shaft. the correct position located on
its pivot pin.

With the spring in position slide Slide clutch ring over centre
the cam onto the end of the column ensuring splines are
shaft with the spring loaded engaged.
finger pointing down.
It may be necessary to rotate
the shaft slightly from side to
side to engage the cam into the
correct position.

Sizes 40,70,90,91,95 Place the coil spring, steel


washer with its chamfer
only uppermost onto the centre
column n in that order.
Rotate and position the lever to
insert the key into key slot in
Press down on the steel washer
lever shaft.
to compress the spring. Slide
the ’o’ ring over the centre
column and down into its grove.

To make the job safer a clutch


spring compression tool should
be used to compress the spring
to allow the ‘o’ ring to be
released.
Publication 002-047-00 issue 11/12
Module 1G/1 Hand Auto Cam Kit All mechanical sizes
Publication 002-047-00 issue 06/13

Fill Gearbox With Oil

Before fitting hand drive fill


gearcase with fresh oil through
the hand drive aperture, ensure
all oil drain plugs are sealed,
that the sliding clutch coupling
is down in the drive position and
bring the oil level up to the top
of the clutch but no higher.

Oil Capacities
IQ sizes Litres US Pints
10,12,18 0.5 1
20,25 1 2.1
35 1.5 3.2
40,70,90,91,95 3 6.3

Refit Top Handwheel

Check the condition of the ‘O’


ring is serviceable. And sealing
face is satisfactory.

Carefully refit handwheel


assembly ensuring ‘O’ ring is in
position .

Tighten down fixings with 6mm


Allen (hex wrench).
Publication 002-047-00 issue 11/12
Module 1G/1 Hand Auto Cam Kit All mechanical sizes
Publication 002-047-00 issue 06/13

Group ’B’ Bases and


Refit side handwheel Bushes
(if fitted)
Using the correct size circlip
Check the condition of the ‘O’ pliers open the circlip and
ring is serviceable. And sealing relocate the drive bush onto the
face is satisfactory. centre column ensuring the clip
is located in the slot.
Carefully refit side handwheel
assembly ensuring ‘O’ ring is in
position .

Tighten down fixings with 6mm


Allen key (hex wrench)

Refit Cover Tube or


Hub sealing Cap Refit flange adaptor onto
gearcase and secure hex bolts.
The top or side handwheel
should be fitted with a cover
Tube or Sealing Cap to prevent
ingress of moisture to the
centre column area.

Torque values fitting bases

Ensure the ’O’ ring is in position


and serviceable then refit cover
tube or cap. Locate screws and
tighten using Allen key ( hex
wrench)

Refitting Drive Bush Refit Actuator to Valve


or Gearbox if required
Group ‘A’ Bases and
Drive Bushes.
(Types A,Z3)

If the actuator was originaly


removed from the valve
together with its base and drive
coupling then these must be
refitted onto the gearcase.

Carefully align the centre


column drive dogs into drive
coupling and tighten fixings.
Module 1G/1 Hand Auto Cam Kit All mechanical sizes

Publication 002-047-00 issue 06/13

Replace battery
Disconnect the existing battery and using the strap
provided pull out of its plastic holder.
Whilst the actuator is down for
maintenance it is recommended
Fit new battery into strap and push into its holder,
that its battery be changed.
reconnect.
The battery as fitted by Rotork
is generally a PP3 9 volt
Refit and tighten threaded plug after lightly greasing
Ultralife Lithium cell.
thread and checking sealing ‘O’ ring is serviceable.
For Hazardous area certified
units ONLY approved battery
types must be used.

See Below for Approved Battery


Types

BATTERY TYPES

For European hazardous area certified actuators (ATEX / IEC Ex) use a
lithium manganese dioxide battery as stated in Table 1 BELOW.

For FM and CSA certified enclosures use an Ultralife U9VL lithium


manganese dioxide battery. Equivalent, UL recognised, batteries may
be used.

For watertight (WT) actuator enclosures Rotork recommend a lithium


manganese dioxide battery, however any equivalent 9V battery may be
used.

If in doubt regarding the correct battery type, contact Rotork.

Table 1

Enclosure Type Battery Type Detail


ATEX/IEC Ex Ultralife PP3 U9VL or
Standard Temp Types U9VL-J-P Recommission the actuator using Publication Pub 002-039-00 and
the Rotork Bluetooth Setting Tool.
ATEX/IEC Ex Rotork Part Numbers 95-462 or
Low/High Temp 95-614

The battery is situated in its


own compartment located in the
gearcase.

Using an 8mm allen key (hex


wrench) remove the access
plug.
Workshop and Spare Parts Manual
IQ, IQM and IQML Mk 3 Range Actuators
Modules 1K, 1K/1 & 1L Battery
All mechanical sizes
Publication 002-047-00 Issue 06/13

Module 1K consists of the following


components:-

Battery Type PP3 Ultralife U9VL Lithium


Manganese Dioxide.
Battery Cover Plug and ‘O’ Ring.
Battery Removal Strap.

Module 1K/1 consists of :-

Battery only

Module 1L consists of :-

Battery Cover Plug and ‘O’ Ring only.

The Actuator Battery


The battery supports the actuator position
Module 1K updating circuits and the position (LCD)
display when the main power supply is
turned off . It ensures the current position
is displayed when manual operation takes
place with the main power turned off.
The battery is not required to retain any
actuator settings.

WARNING
The battery holder in the actuator
gearcase also protects the user from
the hazardous live connections inside
the actuator and therefore it must not
be damaged. The actuator must be
isolated or disconnected if the battery
holder has to be removed from the
actuator gearcase.
A unique circuit has been incorporated
into the battery function of the IQ,
effectively reducing the overall drain and
significantly increasing the battery life.
Tests show for a typical actuator, a
battery life of 7 years can be expected.
Allowing for a conservative margin,
Rotork recommend that the battery
should be replaced every 5 years.
Battery level status is indicated by an icon
on the actuator display.

Full details from the actuator name plate must be given when enquiring about or ordering spare parts
Workshop and Spare Parts Manual
IQ, IQM and IQML Mk 3 Range Actuators
Modules 1K, 1K/1 & 1L Battery
All mechanical sizes
Publication 002-047-00 Issue 06/13

Replace battery
Disconnect the existing battery and using the strap
provided pull out of its plastic holder.
Whilst the actuator is down for
maintenance it is recommended
Fit new battery into strap and push into its holder,
that its battery be changed.
reconnect.
The battery as fitted by Rotork
is generally a PP3 9 volt
Refit and tighten threaded plug after lightly greasing
Ultralife Lithium cell.
thread and checking sealing ‘O’ ring is serviceable.
For Hazardous area certified
units ONLY approved battery
types must be used.

See Below for Approved Battery


Types

BATTERY TYPES

For European hazardous area certified actuators (ATEX / IEC Ex) use a
lithium manganese dioxide battery as stated in Table 1 BELOW.

For FM and CSA certified enclosures use an Ultralife U9VL lithium


manganese dioxide battery. Equivalent, UL recognised, batteries may
be used.

For watertight (WT) actuator enclosures Rotork recommend a lithium


manganese dioxide battery, however any equivalent 9V battery may be
used.

If in doubt regarding the correct battery type, contact Rotork.

Table 1

Enclosure Type Battery Type Detail


ATEX/IEC Ex Ultralife PP3 U9VL or
Standard Temp Types U9VL-J-P Recommission the actuator using Publication Pub 002-039-00 and
the Rotork Bluetooth Setting Tool.
ATEX/IEC Ex Rotork Part Numbers 95-462 or
Low/High Temp 95-614

The battery is situated in its


own compartment located in the
gearcase.

Using an 8mm allen key (hex


wrench) remove the access
plug.

Full details from the actuator name plate must be given when enquiring about or ordering spare parts