rotor Instruction manual for ‘K’ Range Syncropak and Syncroset electric valve actuators K30, K60, K150, K300, K500, K600, K800 and K1000 actuators Publication BRV6/4 Issue 11/04If your actuator cannot be installed immediately store tin & ‘ry place until required and do not break conduit entry seal until youre ready to wire up. ‘The Rotork double sealed construction will preserve intemal ‘electrical components perfectly, flett undisturbed. Rotork cannot accept responsibilty for deterioration caused onsite once the actuatorcovers are removed. Every Rotork actuator has been fully tested before leaving the factory to give you years of trouble free operation provideditis correctly installed and sealed. Contents Page 1. Operating the actuator 1 2. Position indication 1 93. Actuator bases 2 4, Preparing the drive bush 2 5. Mounting the actuator on the valve 8 6. Setting the switch mechanism 4 7. Wiring up and electrical start up 6 £8. Trouble shooting, lubrication and maintenance 7 THIS IS NOW YOUR PROPERTY, DO NOT DAMAGE IT. DO’S & DONT’S ON ACTUATORS 1. DONOT | use crow bar to it the top cover of wooden casing by Using the actuatorhandwheelas @fulerum point. 2. On opening the case, check actuators for visible damages and take immediate action to notity insurance damages are tied. It damaged parts are not attended especialy on Switch Mech side, the IP 68 sealing effect willbe lost and components may got rusted, 8. Though actuators are made to IP6®, ensure that ifthe actuators are not used immediately, they are stored in a covered dry lace and do not break the seals Le. sealing plugs & screwed ‘collar. therwisethe eect of IP6S willbe lost. 4. When the drive sleeve is taken out for machining and while rofixing, please ensure that the drive slot in the sleeve is in ‘alignment withthe centre column drive dogs. Also ensure that te) “0 Rings are intact and not damaged. DO NOT modlty any ‘sctuatorcomponents withoutourpermission. ‘5. While mounting an actuator onto a valve, please make sure that ‘te comect valve and actuator aro coupled. If an oversized ‘actuators coupled toa valve, then the valve stem will got bent the base will get damaged, Ifthe actuator is too small for the ‘plication, the actuator wil not be able to cose the valve tight shut. 6, DONOT star an actuator at the end of its travel. Always check that the actuator and the valve are in the midway of thelr travel to allow forthe checking ot the rection ot rotation. 7. DO NOT ty to run a syncroset actuator trom direct three phase ‘supply. Always take the power supply through a contol box with Contactors and ensure thatthe correct direction of rotation Is given to the actuator. '8, Always connect the actuator motor thermostat in series wth the contactor colls (both open “& close contactors) for motor protection. 8. DO NOT engage the hand auto lever when the actuator is running. 10. DO NOT use intemal appliances lke pipes and crow bare to increase the leverage of hand auto lever or handwheel. This wal only demage the internal pars of actuator, 11, When engaging the hand auto lever please make sure that he {dogs in clutch ring and handwheal arent against each other. ths ‘can be seen ifthe hand auto lever does not go fully to its stop positon. both the dogs are against each other, release the mans ‘auto lever andtum the handwheelurher by about 45 degr=s 180 of engagement. 12, Please make sure thatthe sealing 0’ Rings arekapt sate when any ofthe actuator covers ara removed. The'O' Fig: — = be undamaged and kept clean. Also onsute to replace ther ‘correct postion when refxing the cover and make sure tnt tro ‘cover screws are fully ightened atter assembly. 419 DO NOT use one operator to engage the hand auto lever and = second operatorto rotate the hand wheel atthe sametime, as :1's Practice may cause damage fo the handwheel dogs and clutch dogs. One operator can engage and operate the hand auto ‘mechanism, ‘14. When the actuators ited tothe valve, DONOT laythe vawve ana the actuator assembly onthe flor such a fashion thatthe total weight ofthe complate value is resting onthe actuator or on the hand auto lever ofthe actuator. Aways res the unit on a wooden block at an angle such that the actuator is clear ofall weight or ‘contact withthe floor or other obstructions and thus damaces are avoided, 15. DONOT itt more than one actuator at atime (oven when using a crane) since damage can be caused by crashing one actus: ‘against another. 16. Insta the actuator as per the instruction manual w' despatched along with each actuator. 17. Ensure isolation of power betore opening electrical comeartment 418. Ensure thatthe valve spindle is kept clean andlighty lubvcated 19. Ensure that covers ae fited correctly a all mes and thatthe coverholding serews are uly tightened 20. Ensure thatthe actuator base holding bolts (wien fited to te valve) are ofthe correc size & length andare fully tightened,1 Operating the actuator All actuators Rotork ‘k’ Range actuators Each "K’ Range Syneroset & Syncropak actuator consists of four basic sub assombies, 1. Motor 2. Ol fited gear box with hand whest and dectuten mechanism. 3. Limitand torque switch mechanism. 4Teminalbox ‘Syneropak actuators also contain integral ‘Stare anc assocated contolequnment. Operating your actuator Manually “To engage handwhes! move hand auto lever In the drection of anow and tum handahest twengage hehang azo mecharssm. ‘Thelevercannowbereleased. ‘The handwhos! drve wil remain engaged Until the actuator is operated electrically When i is operated electically i will ‘automaticaly disengage the handwheel and rotur to ‘Auto. If required, the hand auto levercan be securedin ether postion with & 5/16" diameter hasp pactock Electrically Power supply and other connections shallbe ‘made as per wiring diagram supolied with the actuator Syncroset ‘Syncroset actuators require separate statar facies. ‘Syneropak ‘Syneropak actuators contain their own integralstanterandcontrolcircuts, Selecting ‘Local’ or ‘Remote’ control The black selector switch located on the starter caver can be turned select any one cfthethree contro postions. ‘Local’, Remote’ or ‘Off When selecting Of", note thatthe selector Switch lover rides over the red pushbutton and automaticaly depressesit [Any positon can be maintained by using a 14" hameternasp padiock. ‘To open or close the valve or stop the ‘actuator electrically, ‘The red pushbutton located on the stantor ‘cover has two function, ‘push to stop, turn tostar insitherdrecton, 2Position indication Allactuators Position indication is not supplied as ‘tandardon'K’Range actuators. Local indication Is avaiable as an optional extraintwoforms. 1. Three position, showing “Open’, Intermediate and Closed. 2. Continuous indication trom “Open to ose’ (On syneropak actuators only, local postion indication is ituminated RedYellow/Green {or'Open'/'ntermediat!/"Closed For setting instructions for local postion indicators see section 6 Setting the switch mechanism Remote position indication ' Range Syncroset and Syneropak ‘actuators oan be fitted wth a potentioms for remote postion indication. For soting Instructions see secton 6, ‘Three position indication (chown in ietermeciate postion) Continuous Position indication For Fame Proof Actuator (Shown in intermediate postion) Closed turinatad Perro “Opel eyo Sora © Optonalon Syncropak actuaiow: liuminated indicator window We pin Spat Mibenedt“cosee = 2 rt = = pat 0 c "nai Red__Velow Gren3 Actuator bases All actuators The following options are available a soon BE oe is noe ‘GO (DIN) F10 (SO) A GO (DIN) F10 (SO) Thnst ‘Non-heast ang eur G12 (DIN) F14 (SO) A Gt2 (DIN) F14 (ISO) Ae ae ae e spact rag = 1/2 (DIN) F14 150) E_G1/2 (DIN) F14 (ISO) 8 Giz (DIN) F14,0S0) A Thrust Non-hrust Nonethnust 800/100 ee G3(DIN) F16 (180) Thrust G.9,01N) F16 (so) Nor-thnust 4 Preparing the drive bush ‘Type A thrustbases only Iisnotnecessary to remove the thrust base fromthe ‘actuatorto machine the dive bush. The orive bush ‘can be simply removed from the base for this ‘purpose (see below) Drive bushes can aiso be suppiiod soparately fo: tho ‘purpose of machining, In this caso the thrust base fs supplied wit a dummy bung in place ofthe drive bush fo retain the thrust earings. This should oe femoved when dismanting the thrust base (see below) torefitthe crive bush a.Grease —@, Actuator i-Thnst nipple gearcase race b. Dive bush ©. -O'ng 4. Actuator h. Thasst conte washers column Removing the drive bush Unscrew the two flange retaining screws and remove the base flange. ‘CAUTION ‘The drive bush can now be removed and the thrust aces and washers should also be carefully removed and stored inaclean area. Take care also to prciact the’ ring seas from it and dust ‘The drive bush may now be machined to sut the valve stem or gearbox input shat. Allow apparently ‘excessive clearance on Screw thread for old ising stem valves. Replacing the drive bush Confirm thatthe dive bush isthe coract way un by checking that the slot to fit the actuator centre columnist thetop. CCheckthe integrity ofthe 'O' rng seal inthe top othe aseReplace the first thrust bearing [washerirace/washer) before refiting the ‘tive bush. Replace the second thrust bearing. Check the itegnty and condition of the 'O' rng seal in the base flange and then refit the flange and bolt up with retaining ssorews, ensuring thet the ‘O° ring fis correctly aroundthe drive bush Recharge the thrust base with grease through the nipple. 5 Mounting the actuator on the valve Alactuators Non thrust actuators (Type Bore) “The valve or gearbox shouldbe designed 10 possess dimensions compatible to the ISO fr DIN flange and base dimensions of the ‘actuator, and have @ stem with @ diameter ‘and key machined to f the fied bore ‘ameter and keyway of the actuator centre ‘column. ‘The actuator may then be simply lowered on tothe valve or gearboxstem: ihe key ways ‘not aligned with the key on the valve stem when the actuator is in the correct positon above the stom, engage hand drive ‘and tum the centre column with the hand Wheel untl corect alignment is achieved. With the actuator correcty seated on the ‘valve or gearbox flange, ft securing screws ‘ornutsand tightan fly () Atteratively tho base may be removed ‘tom the actuator for atachment to the valve by removing the four securing bolts. ln this ‘case, the separate base shouldbe ftted over the valve or gearbox stem & key and the ‘securing serene or nus uly tightened. The actuatormay then be lowered onto thebase ‘and the contro column rotated by the hhandwheel until the lugs conectly locate Inge the base to enable correct seating. In this position the securing bolts between the actuatorane the base shoule be replaced and uly tightened. ()Not applicable to K30/60 F7B &E. K600 FisorGi/2B8E or K 1000F 6rG3B&E. Thrust-taking actuators (Type A) ‘Allthrusttaking actuators are supplied with a ‘soparato thrust base which conforms to ‘either ISO or DIN type standard dimensions. ‘These bases contain a separate aluminium bronze drive bush or machining to suit the valve or gearbox stem. For machining instructions see section 4 “The separate thrust base facfty means that the aotuatorand thrust base can eitherbe mounted on the valve as a compete unit or the thrust base can be removed from the ‘actuator for mounting onthe valve, and then the actuator refited othe tust base, In either case, the separate thrust base teature faiitates the removal ofthe actuator {rom the base at any ime for maintenance or Inspection purpose without releasing stem thrust inthe valve, which ie contained in the theustbase. Mounting the actuator with thrust baseattached “The valve should have mounting flange to ut the actuator base ‘lange dimensions. Make sure thatthe valve mounting flange is atrightangles tothe inputshaft Rising stem, top mounting Lower the actuator onto the valve stem Engage the actuator handwheel and wind the centre column and drive bush in the ‘opening drection to engage the thread on ‘the valve stem. Continue winding until the ‘actuator is fimiy positoned on the valve yoke. Wind two further turns on the hhandahee, ft sectring screws or nuts and tighten fully Valve/Gearboxes-side mounting ‘Check that the valve mounting flange Is at fight angles fo the input shaft and that the ‘we bush fs he shaft and keyway with ‘adequate axial tolerance. Engage the ‘actuator Randwhee! and ft the actuator to the shaft. Tum the drive bush by the hhandwheel to align the keyway and key neues that actuator and valve flange aro ‘seated corecty and boltup ight. Applicable ‘oniyfor type coupling Non rising stem valves - top mounting ‘Same as gearbox side mounting and ensure that the thrust nut above the drive bush on the end of the valve stem is securely gntenes Mounting the thrust base separately fromthe actuator The valve mounting flange should have ‘dimension to sultthe actuator ange and the input shat shoud beat theright angles othe valve tange. ‘Ascerai from name-plate the base ited to ‘your actuator. Rising stem valves, top mounting Pace the thrust base over the valve siem ‘and tur crive bush by hand to engage the thread. Continue winding unt the trust ft bbase is seated on the vale yoke and 1 ‘Securing screws or nuts, Engage the actuator handwneel and lowe" the actuator over the thrust base. Rotate the contre column by the handwhee! until tne lugs at the bottom of the centre column ‘correspond withthe sltinthe top of the due ‘bush. Bol the actuator tothe thrust base ‘Wind the hancwhee in the opening cirecion fortwo tums and then relighten the securing ‘serensornutsonthevalveflange. Valve gearboxes-side mounting Make sure thatthe valve mounting a at right angles tothe input shat an ors! ve bush fhe the shat and key way > adequate axial tolerance. Tum push by hand until the keyway 255 ‘the key on the input shaft, push the base onto the valve flange ang bo! ‘Atach the actuator to the thrust case as above, it is not necessary fo retighten the securing bolts on the walve flange atte: attaching the actuator to the trust base Non-rising stem valves - top mounting ‘Same as vale gearbox side mou ensure that stmt above the v= ‘bush on the valve stom is securely 6 Setting the switch mechanism Allactuators ‘The torque sensing linkage is factory set during performance testing and rmustnotbe distributed. “There are two basic operations that have to bocaredout: 1. Setting the switches to operate at endo valve stroke.2, Selecting the correct torque’ or ‘it function for your paricular valve and Aagjusting the torque value for your particular application Hf you received a complete motorised valve both these points should have already been carriedout How to check if your switch mechanism has been correctly set Ifthe actuator is equipped with 3 positon local indication, engage Randwheel drive ‘and wind the vaNe fuly open and fully closed. I! the pointer is reading corecty at ‘each end of stroke you can assume that the valve maker has correctly carried out the setng instructions. IW your actuator has continuous local indleation, engage handwheel ceive and wind the vaive fully open and fully closed. the pointaris reading comectiyateach end of stroke you can assume that the valve maker has correctly carried out the setting Instructions. Hf your actuator has continuous local Indication, it is driven by a separate fattachment to the switch mechanism. ‘Therefore, even fitoperates correctly during the above check the switch mechanism may stil natbe correctly set Proceod asbelow. Remove switch mechanism cover by Lnserowing 4 Nos. of MB Screw oncover For ‘ease of cover extraction Mi tapped holes 2 coffareprovided on cover Engage handwheel sive and put vale in ‘mig’ postion. Note the poston ofthe teo pointers on the ends of shat 6) and (7) on {he switch mechan'sm which should be Doing towards the orquerim selecoss (4) and (6) Winathe ve uly closed. the ‘mechanisms corecty setthe poiteron he “Diose’ side of the mechanism should tum rticlockwise trough 80 at the end ofthe valve travel to denote the operation ofthe ‘Ciose torque swatch, peat the operation in the ‘Open’ rection. Note that atthe end of stroke the pointer on the Open’ side of tie mechanism should turn lockevie through 9 necessary to go tough the following procedure, Do not operate the actuator with power, on ‘Limits’, without setting the switch mechanism. Setting the switch mechanism to operate on ‘Limit’. Tool required: scrowariver 1. Set the forquelimt selector shafts (4 and 5)t0thetorqueposiion, 2. Engage handwhee! drive and wind the valveto the fully closed poston 3. Free the drive pinion by depressing shaft ({) with a screwdriver and tum anticlockwise in direction of artow on Closo side of switch mechanism (shaft should remain in tis position when scrowdtverisreleased) 4.Tumshaft (2) siowl through ratchotpoints in dtection of arrow until the indicator pin in shaft [6] has tured and is pointing towards the astorisk mark [7] and shatt [2] is against the firstratchet point this ratchet pointis assed, continue to turn shaft 2] untl the indicator pin is again pointing towards tho asterick mark. It Inclcator pin is already pointing towards the tor'sk mark" of switch mechanism, donct automatically assume that switch ‘mechanism is set, but carry out he above instruction [4] unt indicator pin has ‘completed afultur. 5 Depress and tum shaft [1] clockwise to ‘mic: postion eothat tsorings forward. {6 Wea tho valve fully in tne OPEN direction ‘and ensure that shaft (6 moves away from he asterisk mark {"] by 90". If happens ‘continue from step [11], The setting is Improper tins does not nappen. 7. Wind valve tote fully open postion. 1 Free the crve pinion by depressing shaft [il wh sorewariver and tum clockwise in ‘Grecton of arrow on Open side of switch ‘mechanism. [Shaft should remain in this [postion when screwdriverisreleased), '@-Tum shaft [3] slonty through ratchet points fe Girecton of arrow unt indicator pin shaft [7] has tured and is pointing towards the ‘asterisk mark ["] and shaft [3] s against the ‘st ratchet point. If this ratchet point is (passed, continue to tum shalt [3] untl Jecicator pin Is again pointing towards the ‘asterisk mark(" If indicator pin is alady pointing towards ‘steskmark["Jol switch mechanism, donot utomatically assume that tne switch ‘mechanism is set, but cary out above step 40, Depress and tur shat [1] anticlockwise ‘tomic-postion sothatit springs forwarc ‘1.Wingthne valvein he’ Ciose’ drection and ‘ensure that shaft [7] moves away from tho ‘asterisk mark ["] by 90°. The setting is improper if this does not happen, repost stops 7 through 10. ‘The switch mechanism is now selected to ‘operate on “orque’ al each end of stroke, bu iRnow must be decided whether the valve ‘should operato on ‘Limit or on ‘Torque’ in ther the ‘Opon’ or ‘Close’ cirections. The Necessary torque values for "Toraue ‘operation shouldnow be decided. In the absonce of specific valvemakers instructions, use the folowing basic table, ‘Close Valve ype ‘Open Wedge oat, Globe Tore Lime ‘Through Conduit Pieine} Ball, Plug Siuice gate Buttery Limit Limit Torque'Limit selectors [4] and [5] shou'c now be sot to thelr appropriate functo {Based onthe above table] ‘The torque values can nom be seton 32 and} In the opening direction [9] we recommend that you set the pointer to the minimum setting by unscrewing the locking screw and turing the pointer tothe 40% position. You should be prepared to incroase this vive ‘dunng stan up to overcome any running torque inthe valve. In tne closing rection also we recommend ‘that you set the pointer [8] to the minimum sting infialy @s only the minimum torque necessary to achieve tight shut-off should be ‘applied, Howover, you shouldbe proparedto Imerease this value during star-up Wa tan ‘shutoffisnotbeing achieved. Setting the independent limit switches [if fitted] Each of the Independent limit switches situatedionthe Auxiliary Postion Drive (APO) can be Set to operate any pont in travel. To set each switch, run the valve to required position andiusing a small screwdriver adjust the cam as @ pair to operate the required ‘ovitch. The Gwell [period the sviton is ‘operated can be adjusted 10 suit various ‘ums by packing of one halfoftne car, Setting the indicator dials Uitfitted] Three position indication ‘Three postionindication is automatically set whentheswitch mecharismis correctly ectContinuous position indication For'Flame Proof Actuator: Continuous postion indication is situated on ‘the Auxillary Poston Drve [APD] assembly and snot therefore automaticaly set by the ‘poration ofthe switen mechanism. 1. Pun or wind the valve tuly closed 2. Tum the selector shaft [1] clockwise unt the pin Is poining at the stop screw [f indicator lights fitted, at this point he green lass flag should be postioned over the bulb) 8. Slacken pointer xing screw [2]and aciust pointe [3] to the ‘Closed’ symbol. Retighten ‘Closed tuminatod (1) Potentometer symbol indeator” gear ve cater ywincow fc) ° (4) pen symoot Pane Finng—_(aastabie or Seow Gachvehe) 4. Rumor wind the valve fully open, ‘5. Adjust the ‘Open’ symbol [¢] until the ‘symbol corresponds with the pointer position. For ‘Watertight’ Actuator 1. Run or wind he vale fly closed. 2. Tur the selector shaf [1] clockwise unt the pin is pointng at the stopper pin ft indicator ight fit, at this point the green lass flag should be posiioned over the but. 8. Fixthe close sier(2) at one postion and ‘2gustthe pointer (3) tothe cosed symbol in the close ser. (4). open sider adjustable. (3) Pointer ‘Open Setting the potentiometer(iffitted) 1. Run orwinathe valve fully open. 2, Note the number onthe label to wnich the {98a crve selector pin (1) pointing (For WT actuators the label is fixed behind the Indicator plate). 3. Retertothe table below to ascertain which potentemeter cluster goar[No.12 of gure ‘shown on page 6] 10 mesh wth the main euch gear [No.14 of figure shown on Pages) Selector Potentiometer Labal umber Gear Number i 1 [Smallest] 2 2 2 3 s 4 (Largest) 4. Slide the potentiometer along the mounting pillar to the appropriate goat. Belore engaging goars rotate potentiometer spindle tits open end of ravel. Engage the {gearsandciamp potentiometerin position. ‘The potentiometer will now setitsel to zero when the value shut. Setting the Current Position ‘Transmitter [CPT] [iffitted] For both syncroset and syncropak actuators 2wite GPTs [420 ma] are supplied Standard. f 3 wire [0-20 mA] operation is desired, change link 1 Position SW on CPT PCB, Performance ‘The maximum total extemal impedance not to exceed 450 ohms, amblent temperature range-30°C 10+ 70°C. Ouput stability better than 1% with supply variation of + 10% on ‘24V nominal ‘Transducer accuracy is 1%. ‘Absolute accuracy s a function of valvo and ‘actuator gearing backlash, but repeatability |s within + 1% % and linearity + 24% approximately, of actuatoroutput Make the connection at Terminal companment as shown 4. Syneroset (Externally Powered) (1) Selectorshant —umineted indicator window 4, Flun (ot) windthe valve fully ‘open’. 5. Adjust the ‘Open’ symbol (4) uni the symbol corresponds with the pointer 3 Pr. 2, Syneropak (Intemally Powered) | cer 3. Syncropak (Externally Powered) ome. @ —— externa (8 sia corr. Note For 3 wie operation After the appropriate connections are! 1. Runorwind the valve fuly ‘cose! 2, Rast tha “Zero vim pot on CPT PCE til the Ammeter reads 4mA (in case ot 2 wir) ‘andOmaA(incase of 3 wire). 3.Run or wind the valve fully “Oses 4. Adjust the ‘Span’ tm pot on GPT PCB ti ‘the Ammeter reads 20mA, Replacing the switch mechanism cover Rett the cover by replacing the ‘0 ring and tightan the cover with 4 Nos. of MB Cap Folomatic proportional control Setting the CPT(if provided) «2. Chack whether valve is clockwise or at clockwiseto cose. '. Using figure (next page) locate tne dual links J7, For clockwige to cose vale with ow signal at close, ink J7 must be postiones paralleltothe edge ofthe PCB. ©. For clockwise to close valves with low signal at open, and for anti-clockwise to lose with low signal at closet nk J7 must be pastioned at nght angles to the edge the PCB. 4. Forseting refer procedure above ~Setting the Folomatic Zero/Span/Timer/Deadband ‘he Folonato Pop ona module {ce teva soso rang fo an met Sia! win asa a an Span clio. loro Ne Migr ceed inne’ ecumor a auo be. catomers Incr onadeoting When the actuator Lecalott/Remote selector is Set to ‘Loca the actuator functions like any other with OperStop/Close local contr. The actuator should therefore be set to wor intaly under local control in accordance with this instruction took. ‘The folowing instructions are for actuators with Folomatic settings behind the pushbutton cover. 1. Determine whether the valve is clockwise cot anti-clockwise to close and also whether 's toopencnalowdemand signal. Using above figure locate switches 1 and 2, selectastolows: 12. For clockwise closing valves input ow to dose, SW! selected towards edge of ‘board, SW2 selectecaway edge of boars. Input signal low o open, SW! selectedaway ‘tom edge of board, SW2 selected tomar 2492 ofboard '.Forant-clockwise closing valves Input signal low to close, SW! and SW2 ‘away from edge of board _ Input signal low to open, SWI and Swe towards edge of board. 2. Determine what contol input signal {eing to be used. Reter to table abows anc locate the block of DIL switches and select the range required Note: If the range required was indicated st ‘the time of ordering the corect range wl set I not then the Folomatic wil Be set for 4 20mA, ‘3. When usinga4-20mA control oop signit is possible to select whether the actuator wal ‘slay put or fail tothe 4mA end of rawel on loss of signal. Switch No, 1on the Folomatic DiL switchestobe selected'on. Switches 2.3 and 2.4 on main board DIL switches ‘Both selected ‘on’ gives fall tothe close enc of travel Both celectes ‘ol gives fal tothe open end of travel ‘One switch ‘off and one ‘on’ will give ‘stay put. 4. Check that incoming control cables are ‘connected tothe folowing ‘8, Curent or voltage signal to 13 (ve) and ‘22(+ve),oralterativaly b. Customers potentiometer derived signal 10 13, 22 wiperand3 5. with. actuator set t8 tool control run the valve to the nominated low signal end of vavel, 66 Setinputtorequredminimum valve T.Locate the Zoro’ trimmer and adjust unt Be green indicator (i valve is at closed [pestion) oF red incicator (if valve is at open fpestion) on the PCB just lights, ether ‘Resting oF steady, clockwse movement of 220 firmer vil iluminate the appropriate Isicator (Before proceeding. if both Feciators glow simultaneously, rotate zero [Petenticlockor span pot clock wise until both Fecators tno). |B. Operate the valve tothe opposite end of ‘exvel(high signal) using ocalcontro |S Set nut signal to its required maximum level 40 Locate the ‘Span’ vimmor and adjust {268 the re indicator (valve is atthe open (Postion) o° green indicator (it valve Is at ‘Gosed poston) on he PCB just ght, ether aching or steady. Anticlockwise movement ff the span trimmer wil liuminate the ‘Sopropriatcinccator. “7 Set Local Memate selector to ‘Remote’. ‘The actuator ie available for Folomatc emote contol to give ful valve stroke with ‘maximum input signal 412. Deasband adjustment HF the actuator overshoots or responds Uunnecessarily to small changes in signal, increase the deadband by turing the Geadband control clockwise. if greater Folomatic PCB DIL swich sattings voltage or current ranges Range Wi SW2 SWS SW4 SWS SWE SW7 SWE osm OO O a oq om O O o ozma OO a 420m a osm OO : a ov OF D a a oo OF O 5 o ov Oo o o gor SS¥71 OF - custo runs low sonal nd fave! on oss non etegnal SSW On- actuator responds on os of sgnal according 0 Thowon —_prontyectngorman PCB emtence ‘sensivty Is required reduce deacband by fuming anticlockwise. Check thet hurting does not oceur eg. when the actuator moving inthe increasing signal direction, ‘should stop when the balance between the input signal and the actualor fecct potentiometers achieved without the a'2er light flashing after the red lamp has extinguished. fhuning does occur, ncreese the deadband as necessary Motion inhibit timer adjustment ‘The red and green indicators on incicatea change of signalsiate: ‘Red. inthe open position Gregn=in he cose postion stor insces = change of signal state that is bens prevented from operating the actuator for 2 predetermined length of time. This mcton [nhibittme is adjustable between 2 seconde ‘and 40. seconds. {o. sult ste conditions However itis advisable to reduce the diay time (anticlockwise adjustment ‘of the trimmer) to minimum during the seting uP procedure. 7 Wiring up and electrical startup Allactuators BB sip tage agrees vit Sanpaion ne ochuator fern Ground connections A tug wah 7mm dameter hole is cast fagjasent to the conduit entries for Stiachment of an external earthing sap by futandbbot An internal earth terminalis also provided. Removing the terminal cover Flomove the terminal housing cover by lunsorewing 4 Nos. of MB cap screws. Flemowe te 0 ting seal and put asice satay, ‘Connecting terminals Rater 10 the wing diagram inside the emmnal cover to laentty the functions of the terminals: Wirethe powerterminals,Replacing the terminal cover Replace the ‘ring on the housing cover's ‘spigot and push ine cover over itanc tighten ‘tho cover with 4 Nos. of MBcap screws. Electrical start-up -Syncropak Check that imi ewitehes have been set, 986 sections. Operating on ‘Local’ control I valve opens, run valve to fll travel in ‘Open’ and ‘Cioee’ directions. Hf actuator stops prematurely, may be due to t00 low a Torgue setting, increase if necessary, see ‘secion®. For valves precisely controlled by position lt check that valvemaker's mark on valve is reached, Innot tis due 10 incorectly set Limit Switches, se0 section 6. FRoplace stem cover and tum salector swtch to appropriate position and padlock if required. Electrical start-up -Syncroset ‘Check that it switches have been set ee section 6. Cheok that torquelit switch ‘connections with control panel have. been ‘made as per wing clagram suppliod withthe actuator Checking phase rotation (3 phase ‘onty) vate stom is not visible, romove stom ‘cover te Sbserve direction of outpu rotation. Trandwheel and wind valve to ‘Switch on power supply mere aren pusnbuttons within sight ofthe ‘actuator arrange telephone link between ‘conto! stalon and the observer at the ‘actuator. Press ‘Open’ button. if phase rotation is correct, valve should open. It vaNe stars losing, stop immediately. If hare is no local Stop push-button, engage hand auto lever immediately and hold in hand drive unt remote stop buttons operated. CCorrect phase rotation by exchanging any {wo oftoo phase sup leads on power terminals. Ih vahe opens, run valve to full travel in "Open’ and Ciose' directions. Itactuatorstops prematurely tmay be duete too low’ a torque satting. Increase it necessary soe soction6. For valves precisely controled by postion Init chock that valvemaker's mark on valve is reached. If not, tis due Io incorecty set Tmt swtcnes, se2 Section 6. Repiaco stom Motor protection Motors have a direct temperature sensing thermostat embedded in the stator windings {or effective motor protaction. This must be Connected in ne control cult atthe ie of Wweing up and prior to etectricl start-up In caseof Syncrosetactuctors. ‘Space Heater (Optional extra) ‘A space heater is provided against spectic requisiion. if provided this must De connected for ‘electve provention of ‘Sondeneatlon in Switch Mech compartment 8 Trouble Shooting, Lubrication and Maintenance Allactuators Ensure hand auto ever is not padlocked in hand ‘belore trouble shooting unless. you ‘wih to run motor without driving the valve ‘Syncropak actuators Actuators fails to start on ramate contro! “The packaged controls of Rotor Syncropak make faut ecation simp Set selector Swe to,ocal’ and switch on ower supply. the actuator starts correct in ach diection when me pushouton is Lumed the faut an any be inthe remote Contolcreut. & ‘Actuator tals to startonlocaleontol Set soecorewich laa! ard swich on Dower supply. actuator falls to start remove ferminal and check that all three phase terminals are ve with the corect vohage. Indicated on the nameplate anc that 24 DC Isavalable atterminals (and 5). motoris, very hot, thermostats would Pave tipped, ‘which would disconnect conto supply. Check transtormer fuses and replace it necessary. Syncroset actuators ‘Actuatorstalisto start tiyee phase terminals are lve wih the Correct votlage as indealed on the name plate H motor is very ot, thermostat would have tipped, to produce an open ecuit between terminals (43) and (4). Valve jammed Likely causes: 1. Reversed pase rotation. See section7. 2. Limit switches not set correct. See ‘section6. Freeing the valve -jammed open Put actuator in hand’ operation and utis= the hammerblow feature in the closing ‘rection untiinevalveis reed, Freeing the valve-jammedclose For thrust taking actuators (Type A) loosen the actuator mounting bolts eveniy fo release thrust. Free the valve by hand and retgaten themounting bots. For non-shrast actuators Type) all thus Contained In the valve / gear box anc Therefore tno valveraker's advice shoulc bosought. ‘Valve not seating correctly Likely cause: 1.The Close’ torquo'fimit selectorhas been setto limit rsetto torque’, see secton 6 2. The ‘close torque’ seting is too Increase as necessary, see section 6. Actuator runs without driving valve Lkely causes: 1 Hand aut lever padlockin hand. 2 Actuator / val dive nat corey ‘meshod, sae section 4, Lubrication and maintenance Oil Unless speciicaly ordered for extreme Climatic conditions, rotork. actuators 32 ‘despatched with Gearcase filed with SAE EP oll (or) ALPHA Sp68. suitable 10 ambient temperature’ ranging trom *0C10+70. 300, $00, 600, 800 and 1000 actuators are ‘equipped wih lil drain plugs. The use of the plugs provided is determined by tne ‘mounting postion on the vaWve. Always fo thelovelolthe uppermost plug, (On tho K90, 60 and 150 actuators rove ‘ha handnngl assembly by unserurny ans removing te retaning bot anon rearing car at fo topo he Gatco tmpy or the Goarease win ol Capac) sai. Maintenance After six months operation tighton mounting bots It your actuator nas been propery instated and. sealed, normal valve operation produoss ile wear and tear, so Po route Fraintenance is recommenced beyond the Tpncation ef valve stems and nuts. It the motorised valve is rarely operated. 2 routine operating schedule should be et up {tis recommended that the "0" args 10.86 changedif found damaged detormes.SETTING CONTINUOUS INDICATOR (IF FITTED) 1. Ensure the gears (6) and spacers (5) are of correct nos. in the APD assembly as per the chart for the number of turns. 2. Add or delete the gears and spacers as per the chart. 3. To change gears and spacers follow the instructions listed below a. First remove two M6 Nyloo Nuts (1) by using 10 x 11 spanner and remove the APD. b. Remove the M6 Cap screws (2) using Allenkey 2.5 mm given in spares kit, ©. Pullthe plate (3) squarely andtake it out. d. Now take out the drive adaptor (4) and all spacers (5). If you want to add the gears (6) add pair by pair and if you want to delete the gears delete pair by pair. fe. Now check that the number of gears (6) are corrects perthe chartonpage No.9. . Fill up the space by number of spacers (5) as per the chart and put the drive adaptor (4)attheend, |. Put the plate (3) back in position, with correct alignment to gearshaft (7), clutch shaft (8) and pillars (9), Tighten the M3 Cap screws (2) and ensure all switches are back in their correct position, if not correct, resettheirposition. Ensure the gears mesh properly and the assembly isfreeto otateinbothirections by hand Refit APD assembly fomounting studs (10) after frst checking that the mounting studs (10) are fully tight against the mounting plate (13) fix with M6 Nyioc nuts (1). After ensuring correct engagement of drive adaptor and drive pin, fully tighten nuts (1). Now the APDiis set for requited tums of the actuator,zvaee. ‘sua0vds = Tas] Si suva9 4O waawnNn _— a Tr ae To 009 oo'osr-to'992 | oogs2-to'0et Joo'oet-l0'9 | oo're-to7ze | ooze-1e's1 | onst-eaz | zez-iee | o8e-00z | (ais) He | om | olla SNUYNL LNdLNO HOLVNLOV Houims | HOLWALOv INN LYVHS NOLLOATAS HV39 Adv SDNVY oyRegd. Office & Chennai Factory Rotork Controls (India) Private Limited 28.8 Ambattur Industral Estate (North) (Chenrai 600 088. India telephone (91 44) 26254219 teletax (91 44) 26257108 Branches Rotork Controls (India) Private Limited 304 Shrikant Chambers Third Floor ‘Sion - Trombay Read, Chombur Mumbai - 400 071. Inia telephone (91 22) 25204678 twlotax (91 22) 25204540 Principals Rotork Controls Limited At S10 Batn England etephone (01225) 793200 fesetax (01225) 59467 Rotork Controls (India) Private Limited £606 Suneja Towers Il Janakpun District entre iNew Delhi 110 088. Inia ‘seiephone (91 11) 25616305 felephone (91 11) 25502840 Bangalore Factory ROTORK CONTROLS (INDIA) PVT. LTD., 165/166, Bommasandra -Jigani Link Road, KIADB industrial Area, Anekal Taluk, 862 106. Rotork Controls (India) Private Limited ‘Shanthiniketan, nd Floor ‘Suite No. 6 8, Camae Street. Caleutia-700 017. India telephone (31 $3) 22623206 teletax (91 33) 22823473 12