K Range

High Torque
Electric Valve Actuators

Redefining Flow Control

 Contents

Section Page

K Range Actuator 3
K Range High Torque Features 4
Enclosure Options 5
Drive Options 6
K Range Performance Summary 7
Actuator Motors 8
Wiring Diagram 9
Dimensional Drawings 10

Rotork is the global market leader in valve

automation and flow control. Our products and
services are helping organisations around the
world to improve efficiency, assure safety and
protect the environment.

We strive always for technical excellence, innovation and

the highest quality standards in everything we do. As a
result, our people and products remain at the forefront of
flow control technology.
Uncompromising reliability is a feature of our entire product
range, from our flagship electric actuator range through to
our pneumatic, hydraulic and electro-hydraulic actuators, as
well as instruments, gearboxes and valve accessories.
Rotork is committed to providing first class support to
each client throughout the whole life of their plant, from
initial site surveys to installation, maintenance, audits and
repair. From our network of national and international
offices, our engineers work around the clock to maintain
our position of trust.
Rotork. Redefining flow control.

2
K Range Actuator

With the K Range high torque actuator,

Rotork is now able to offer all the proven
design advantages of its established ranges at
higher torque values than have previously been
possible. Available in three models, K4000,
K5500 and K7000, these actuators offer torque
ratings of up to 7000 Nm and thrust ratings of
up to 1115 kN.

Standard K Range high torque features include:

• Double-sealing against the environment,
protecting electrical integrity at all times
• Standard wiring diagrams for any valve type
• Thrust or non-thrust mounting flange dimensions
to International (ISO) valve standards
• Advanced counter switch mechanism featuring
combined torque position limit switches at each
end of travel
• Integral starter and control circuit option
(Rotork Syncropak)
• Three base options for each size of actuator
• Watertight enclosures

Redefining Flow Control 3

K Range High Torque Features

Syncroset
Syncroset actuators incorporate the motor and limit and
6 torque switches only. This minimizes the electrical equipment
at the valve location and is therefore particularly suitable for
locations where access is difficult or where excessive vibration
may be experienced. However the reversing starter must be
separately specified, purchased, installed and tested by the
1 3 customer and the valve control system is therefore incomplete
4 until wired in the field.

2 Remote
control
Three
phase
indication
power
and
supply
interlocks

Features
Reversing
1. Low ratio worm / wormwheel gear combined with contactor
starter
final spur reduction gear offering a combined drive efficiency
above that of conventional worm reduction designs. The
gearcase is oil filled for normal operation in a temperature Auxilary
limit
Motor
and
Travel limit
and torque
Local
Controls
range of -30 to +70 oC. switches thermostat switches

2. Separate thrust bases providing increased stem

acceptance and thrust if required. Base and flange dimensions
to ISO standards.
3. Very advanced all metal counter switch mechanism
featuring combined torque and position switch with torque
switch latch which prevents valve hammering throughout
travel with non-self-locking gears. Switch mechanism is
quickly and easily set using only a conventional screwdriver.
As with other Rotork designs, the reaction force on the
wormshaft, in direct proportion to the output torque is used
to trip the 'Open' and 'Close' adjustable torque switches.
4. Built-in squirrel cage motor with winding thermostat,
specially designed for valve operation and combining low
inertia with high torque. Class F insulation as standard.
5. Hammerblow backlash feature permitting motor to gain
full speed before unsticking tight stem nuts, etc.
6. Hand/auto selector lever insures positive engagement
of handwheel drive. Power drive automatically restored
by motor start unless lever padlocked to prevent it.
Generously proportioned wormdrive handwheel provided
as standard operating through hammerblow mechanism.
The side handwheel ratio is 90:1 giving a mechanical
advantage of 33:1.
7. High output speeds at high torque enable large valves
to be operated quickly and permit favorable top mounted
actuator configuration.
Syncropak
Rotork Syncropak actuators incorporate the starter and local
controls with considerable economy in site wiring as shown.
This arrangement also enables the essential elements of the
valve control system to be factory wired and tested and sealed
by Rotork Quality Control. Because Syncropak incorporates
everything required for operation from a three phase supply,
it can be tested on local control by the valvemaker and site
contractor with undivided contractual responsibility by Rotork
for reliable operation. Syncropak options increase economy
and add system reliability by providing a high degree of fault
monitoring. Interposing relays enable light current cable to be
used for distant remote control and indication. See publication
RCIE - 34 for details.
Note: 'K' Range high torque actuators are manufactured with
the same wiring diagram options as the Rotork 'K' Range
product. In addition, the 'K' Range high torque counter switch
mechanism can accept both extra end position and mid
position switches.
Remote
Three
control
indication
phase
power
and
supply
interlocks

Syncropak or Syncroset? Reversing Local

contactor Controls
starter
Any motorised valve requires a reversing contactor starter to
Auxilary Motor Travel limit
switch the three phase motor in response to control signals. limit and and torque
switches thermostat switches
This may be separately installed or incorporated in the
actuator. Rotork Syncroset actuators require separate starter
facilities. Rotork Syncropak actuators contain their own starter
and control equipment in a factory sealed and tested package.

4
 `O' ring
Enclosure Options

Enclosure options
All 'K' Range high torque actuators are o-ring sealed from the
environment and the exclusive Rotork 'double-sealed' feature
means that the terminal compartment is separately sealed
from the rest of the enclosure to insure that the actuator is
permanently protected even during long periods of on-site
wiring when the terminal cover is removed.

`O' ring

Redefining Flow Control 5

 205
Drive Options

173
79
114

5
Drive Options F40A 260
8 holes drilled thro'
Three basic output drive column assemblies are available as The F40A is a larger version of the F35AL
34 equi.spaced 356 PCDseparate base

standard on all sizes of ‘K’ Range high torque actuators. which provides enlarged stem acceptance and maximum
415
thrust rating.
Dimensions shown below are to International (ISO)
dimensions.
50 Pilot bore

F35E
The F35E is the basic torque only form. The center column is
terminated with a Type 'E' bore diameter and keyway suitable
for attachment to valve makers' gearbox, etc.

M36

260

224
40 55
82

127

5
M30 300
8 holes drilled thro'
40 equi.spaced 406 PCD

476
45

* Note: Optional Flange Type 3 & Type 4 with the following

260 dimensions can be offered
5

356 PCD
8 Holes drilled and tapped
Type 3 : 8 x M24 x 216 spigot dia x 356 PCD x 415 OD
82

M30 equi. spaced 415

Type 4 : 8 x M30 x 230 spigot dia x 406 PCD x 476 OD

M30

F35AL
The F35AL is a separate thrust base which is added to the
standard gearcase and which contains its own sealed thrust
45

bearing and aluminum bronze drive bush. This feature

260
5

maintains the maximum rising stem acceptance available

356 PCD
205

8through
Holes drilled the actuator center column which
and tapped in this form is
173

M30 equi. spaced 415

simply fitted with a pair of male dogs which engage with the
79

drive bush.
114
5

260
8 holes drilled thro'
34 equi.spaced 356 PCD

415

50 Pilot bore
205

173
79

114
5

260
8 holes drilled thro'
34 equi.spaced 356 PCD

M36
260

415
224
40 55

50 Pilot bore

127
5

300
8 holes drilled thro'
40 equi.spaced 406 PCD

476

M36
260

224
40 55

127
5

300
8 holes drilled thro'
equi.spaced 406 PCD
K Range Performance Summary

Performance Data

Spindle acceptance
Max. Rated
Actuator Size Rising Non-rising Thrust Torque
(mm) (mm) (kN) (Nm)

K4000 F35E - 82 - 4,000

K4000 F35AL 110 95 446 4,000
K4000 F40A 125 105 1,115 4,000

K5500 F35E - 82 - 5,500

K5500 F35AL 110 95 446 5,500
K5500 F40A 125 105 1,115 5,500

K7000 F35E - 82 - 7,000

K7000 F35AL 110 95 446 7,000
K7000 F40A 125 105 1,115 7,000

Stall torque is 1.2-1.6 of rated torque. Limit switch turns range for all sizes is 5-1250 output turns.

Output Approx. Current A (Amps) Av. Load

Actuator Size Power Efficiency
Motor Speed
Locked Rated Nominal Factor (%)
(rpm) Av. Load
Rotor Torque (kW)

20 120 35 15 4.8 0.65 65

K4000 30 140 40 21 7.5 0.71 71
40 140 48 21 7.5 0.71 71

415 V 20 140 40 21 7.5 0.71 71

K5500 50 Hz 30 140 51 21 7.5 0.71 71
3-ph 40 160 59 25 9.2 0.70 73
20 140 55 21 7.5 0.71 71
K7000 30 160 65 25 9.2 0.70 73
40 220 65 29 11.3 0.70 77

Note: For other power supply options refer to Rotork.

Redefining Flow Control 7

Actuator Motors
Motors:
Rotork actuator motors are 3-phase, minimum class 'F'
insulated, and high torque low inertia motors of 15 minutes
rating. The motors are spigot mounted and o-ring sealed
to provide complete environmental protection during long
periods of inactivity when condensation build up can otherwise
cause deterioration. Valves have a limited travel and impose a
varying load throughout the stroke and consequently the valve
actuator motor cannot run continuously and conventional
"FULL LOAD" ratings are not relevant.
Hence our motors are short time rated, as the high inertia of
continuously rated motors will inevitably damage the valves
which are basically for "STOP DEAD" applications.
Motor is integral with actuator and hence as standard
protected IP68 – IS/IEC-60529 enclosure.
8
The following performance characteristics are standard
for our motors:
1) A high stalling torque in comparison with that required to
operate and seat valve will be available at high speed for
unseating in with a lost motion hammer blow effect which
is achieved by allowing the motor to reach full speed
before the drive is taken up.
2) A relatively high starting torque to enable the valve
to be inched.
Number of starts
60 starts / hour.
Protection
Thermostat embedded in stator winding.
Bearing
Deep groove sealed ball bearing lubricated for life available.
Fan Cooling
The design of Rotork motors are such that it renders fan
cooling unnecessary to achieve the 15 min rating.
Wiring Diagram

Syncroset wiring
CIRCUIT DRAWN FOR VALVE IN THE SHUT POSITION Diagram/coding

V
U MOTOR WD
W
THERMOSTAT
3ph Connect 43 and
43
44 in series with
44
both contactors.

A- ANTI CLOCKWISE TO CLOSE

B- BACK WIRING ON ILS
C- 110VAC CPT
0 1 2 3 E- ADDITIONAL SWITCHES IN S/ MECH
F- 230VAC CPT
39 G- THREE THERMOSTAT IN MOTOR
OPEN CLOSE 1 2 3 4 5 6 7 8 9 Blinker H- THERMOSTAT ON HEATER
40 I- 3 T.STAT ON MOTOR + ADDL. SWITCHES
J- ADDITIONAL SWITCHES + T.STAT ON HEATER
1 K- 3 T.STAT IN MOTOR + EXTERNAL POSITIONER
3 Heater 5K6 41 L- P/B ASSY + POSITIONER
T/LS 2 M- SEP. 1NO+INC CHANGEOVER TQ/LT SWITCH
42
5 N- ADDL. SW + 3 T.STAT ON MOTOR + 110VAC
CPT
Ref.Note 1

6
4 0- ADDL. SW. + 3 T.STAT ON MOTOR
1NO/1NC CHANGE OVER CONTACTS

P- INTEGRAL PLUG & SOCKET

7 0 1 2 3 4 5 6 7 Q- P/B ASSY. +3 T.STAT ON MOTOR
9 R- ADL. CPT 1K POT
AS1 8 Potentiometer S- 2NO2NC USED AS 1NO1NC IN ILS
11 71 T- IK DUAL GANG POT
12 FR 33
U- P/B ASSY
10 Fixed Resistor 34 V- P/B ASSY. + LAMP FOR CLI

Ref.Note 4
35 W- P/B ASSY. + L/R INDN. SWITCH.
13 X- 230VAC CPT + 3 T.STAT ON MOTOR
AS2 Y- 3 T.STAT ON MOTOR + LAMP FOR CLI
14 Potentiometer
72 Z- 110VAC HEATER
16 FR 36
15
Fixed Resistor 37
38
17
AS3 3- THREE THERMOSTATIN MOTOR
18
A- ANTICLOCKWISE TO CLOSE

Ref.Note 5
20 POT C- EXTERNAL POSITIONER + 230V AC CPT
19 33 D- EXTERNAL POSITIONER + LAMP FOR CLI
34 CPT 24 VDC
- + +
E- ADDITIONAL SWITCH.
21 35 A F- 3 THERMOSTAT + L/R INDN. SWITCH
AS4 G- EXTERNAL POSITIONER + 3 THERMOSTAT.
22 Potentiometer H- THERMOSTAT ON HEATER
33 J- 3 THERMOSTAT + L/R INDN S/W + THERMOSTAT
24
ON HEATER.
23 POT1
34 K- PLUG & SOCKET + ADDITIONAL SWITCH.

Ref.Note 6
35 M- 1K DUAL GANG POT + POSITIONER
N- BLINKER INDICATION.
1 P- POSITIONER + P/B COVER ASSY.
Potentiometer
T/LS 2 R- POSITIONER.
5 36 S- SPECIAL POT 15K
6
POT2 T- 3 THERMISTOR WITH TRIPPING UNIT.
37 U- SYNCROSET + P/B ASSY.
Ref.Note 2

7 38
8
3
4

Ref.Note 5
CPT EXT.SUPPLY
9 33
10 Contactless 24 VDC
34
13 CPT - + +
35 A
14
AS1
1NO+1NC POTENTIAL FREE CONTACTS

15
16
11 - 24 VDC
2 33 EXTERNAL
ZERO
SPAN

12 +
1 32 SUPPLY
32
IKPOT

17 -
CPT with 23
18
isolated O/P 14 + 4--20mA O/P
21
22 35 - +
AS2 35 A
23 34 34
24
19
20 INDEPENDENT LIMIT SWITCH
0 1 2 3 4 5
Ref.Note 8
25
ILS1 57
26
45
29
46
30
AS3 31
1NO/1NC CHANGE OVER CONTACTS

58
ILS2
Back Wiring

Back Wiring

32 47
Ref.Note 7

27 48
28
ILS3 59
49
50

3 60
ILS4
1 51
2 52
4
Combined T/L
Separate T/L

11
9 ILS5 61
Ref.Note 3

10 53
T/LS
Ref.Note 7

12 54
OR 13
TS 15 ILS6 62
55
2NO+2NC POTENTIAL FREE CONTACTS

16
14 56
5
7
8
6
ILS1 ILS2
47
17 45
POTENTIAL FREE CONTACTS

19 46
18 48
20 55
27 53
25 54
2NO+2NC

26 56
AS1 28 57
29 59
31 60
32 58
30 49
21 51
23 52
24 50
22

NOTES :

61 62 63 64
1. Connect 1&2 in series with close contactor 5. C.P.T. connections shown for 2 wire systems,
Connect 4&5 in series with open contactor For 3 wire systems connect 34 to +ve of supply. 53 54 55 56 57 58 59 60

43 44 45 46 47 48 49 50 51 52

2. Connect 1&2 in series with open contactor 6. 1watt single or dual gang pot either 2.5k suitable
33 34 35 36 37 38 39 40 41 42
Connect 5&6 in series with close contactor for 50V AC/DC or 15k suitable for 110C AC/DC
operation. Please specify pot. value while ordering. 21 22 23 24 25 26 27 28 29 30 31 32

3. Connect 1&2 in series with open contactor 11 12 13 14 15 16 17 18 19 20

Connect 9&10 in series with close contactor 7. Code Nos. 2&4 for back wiring. Terminals shown 1 2 3 4 5 6 7 8 9 10
thus on Ref. Note. 7 are when Backwired.
U V W E
4. 100 ohms 1 watt suitable for 50V AC/DC
operation. 8. ILS are independent limit switches which can be
set for any point of travel TERMINAL BLOCK LAYOUT

Redefining Flow Control 9

Dimensional Drawings

Ø 610
540

492

152

448
317
182
143

Ø 416

Ø 457
FACE A

A 460 114
34

238
266

654

Ă203

Ø 203 Ø 242

Ø 260

Actuator Size Output Speed Motor Dimensions

(rpm) (mm)

A B
K4000 40 648 178

K5500 20, 30 648 178

40 756 235

20 648 178
K7000
30, 40 756 235

Bases: Note that F35E bases are integral within the above dimensions.
F35AL and F40A are external bases which bolt to Face A.

10
Dimensional Drawings

Ø 610
540

152
492

448
317
182
143

Ø 416
FACE A

A 460 114

Ø 457
34

238
B

654
Ø 203

Ø 242

Ø 203

343 260

Actuator Size Output Speed Motor Dimensions

(rpm) (mm)

A B
K4000 40 648 178

K5500 20, 30 648 178

40 756 235

20 648 178
K7000
30, 40 756 235

Bases: Note that F35E bases are integral within the above dimensions.
F35AL and F40A are external bases which bolt to Face A.

Redefining Flow Control 11

Redefining Flow Control

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As part of a process of on-going product development, Rotork reserves the right to amend and change
specifications without prior notice. Published data may be subject to change. For the very latest version
release, visit our website at www.rotork.com
PUB009-001-00
The name Rotork is a registered trademark. Rotork recognises all registered trademarks. Published and
Issue 03/15 produced in the UK by Rotork Controls Limited. POWTG0315