Wd210-Ez610-00556_steam Turbine Operation & Maintenance Manual (Part_2b)

Titolo Identificativo Rev.
Pagina Di
title document no. rev. page of
2 1 14
STEAM TURBINE OPERATION AND 0369TXMA*O556 Classe di Riservatezza
MAINTENANCE MANUAL confidential class
2
Volume N. Prodotto/Struttura
volume no. product/structure
2B
Tipo doc. Codice EmittenteTeamcenter Ente Emittente Edizione in lingua Derivato da Rev.
doc. type teamcenter issuer code issued by language derived from rev.
OPM VPFO PTE/TVP ENG

Commessa Progetto Cliente
job no. project client
NUEVA VENTANAS POSCO E&C
0369
Rev. Descrizione
rev. kind of revision
0 First issue
1 Revised where indicated

ELECT.SIGN D:Cagliani C:Cagliani A1:Cagliani A2:- A3:- (22/02/2010)
2 Revised where indicated – Final issue
F.CAGLIANI F.CAGLIANI
2 I TVP/CTEC TVP/CTEC
F.CAGLIANI BERTOZZI F.CAGLIANI
1 I TVP/CTEC PE TVP/CTEC 29.09.2008
F.CAGLIANI BERTOZZI F.CAGLIANI
0 I TVP/CTEC PE TVP/CTEC
Rev Scopo Preparato Controllato Verificato Verificato Approvato Data

rev. scope prepared checked verified verified Approved Date
posco
HYUNDAI
ENGINEERING CO.. LTD.
EMPRESA ELECTRICA VENTANAS S.A.

NUEVA VENTANAS
TITLE 240MW COAL FIRED STEAM TURBINE OPERATION AND MAINTENANCE MANUAL
POWER PROJECT
PREPARED CHECKED REVIEWED APPROVED
Posco
Posco
SIGNA
TURE DWG WD210-EZ610-00556
no.
DATE
Ansaldo Energia s.p.a. si riserva tutti i diritti su questo documento che non può essere riprodotto neppure parzialmente senza la sua autorizzazione scritta
Ansaldo Energia s.p.a. reserves all rights on this document that can not be reproduced in any part without its written consent
Progetto / Titolo Identificativo Rev. Pagina Di
Project / title document no. rev. page of
0369 – NUEVA VENTANAS 2 2 14

0369TXMA*O556 Classe di Riservatezza 2
confidential class
STEAM TURBINE OPERATION AND MAINTENANCE MANUAL

DOCUMENT LIST
Code KKS Description Document/cross reference
CONTENTS
VOLUME 1 A
MA STEAM TURBINE
MAA HP SECTION
VOLUME 1 B
MAB IP SECTION
MAC LP SECTION
MAD BEARINGS AND SUPPORTS
MAK COUPLINGS AND TURNING GEAR
VOLUME 2 A
MAV, MAX LUBE OIL, CONTROL AND PROTECTION SYSTEM
VOLUME 2 B
MAW GLAND SEAL SYSTEM

MAL DRAIN SYSTEM
LBQ, LBS VALVES ON EXTRACTION LINES
VOLUME 3
MA OPERATING MANUAL

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DOCUMENT LIST
VOLUME 1 A
MA STEAM TURBINE
01 General safety prescription 608W542 B
02 Mechanical outline TXMA*M504 4
03 Heavy turbine parts outline TXMA*M510 1 !
04 MA/BU100 ST Thermal insulation drawing 254H273
05 MA/HA851 Hydraulically prestressed foundation bolts 606W561
06 Prestress values and tightening torques 606W562
07 Inspection of turboset by endoscope 606W563
08 Bolt tensioning device 606W626
09 MA/HA900 Hydraulic tightening of elongation bolts 602W620 A
10 Special tool list TXMA*M569
11 Steam turbine wiring diagrams TXMA*E531 5 !


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DOCUMENT LIST
MAA HP TURBINE
1. MAA10 High-pressure turbine HD2O 608W582

2. MAA10/CW71 Balancing of rotors 606W564
3. MAA10CT001 Temperature sensor 612W469
4. MAA10HA/HB400 Reaction blading 606W611

5. MAA10HA400 HP - blading (stationary blades) 248W216
6. MAA10HB400 HP - blading (rotating blades) 248W217
7. MAA10HA400 Identification drawing (stationary blades) 248T191
8. MAA10HB400 Identification drawing (rotating blades) 248T195
9. MAA10HA710 HP gland seal (exhaust end) 606W566
10. MAA10HA720 HP gland seal (inlet end) 606W603
11. MAA10HA900 Shaft lifting bar 232K223 A
12. Shrink ring burner 606W567
13. MAA11AA001 Main stop valve 606W568
14. MAA11AA001 Stop valve actuator SSA 606W651
15. MAA11AA001 SSA actuator cabling 216T175
16. MAA11AA011 Main control valve 606W574
17. MAA11AA011 Control valve actuator STAE 606W575
18. MAA11AA011 STAE actuator cabling 214T357 A
19. MAA11AA061 Check valve insert 606W576

Type: RCV-16/ESH-25

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DOCUMENT LIST
20. MAA11CG011 Inductive displacement transducer 606W514

Type: IW254/064-0.5
21. MAA11AA501 Directional control valve 606W577

Type: 4WE6D5X
22. MAA11AU031 Proportional control valve 606W579

type: KFDG4V-5
23. MAA11AU031 Power amplifier 606W580
MAA11AU031 Inductive displacement transducer see MAA11AU031
24. MAA11BQ001 Swing arm support 606W581
MAA12AA001 Main stop valve see MAA11AA001
MAA12AA001 Stop valve actuator SSA see MAA11AA001
MAA12AA001 SSA actuator cabling see MAA11AA001
MAA12AA011 Main control valve see MAA11AA011
MAA12AA011 Control valve actuator STAE see MAA11AA011
MAA12AA011 STAE actuator cabling see MAA11AA011
MAA12AA061 Check valve insert see MAA11AA061

Type: RCV-16/ESH-25
MAA12CG011 Inductive displacement transducer see MAA11CG011
Type: IW254/064-0.5
MAA12AA501 Directional control valve see MAA11AA501
Type: 4WE6D5X
MAA12AU031 Proportional control valve see MAA11AU031
Type: KFDG4V-5
MAA12AU031 Power amplifier see MAA11AU031
MAA11AU031 Inductive displacement transducer see MAA11AU031
25. MAA11BQ001 Swing arm support see MAA11BQ001


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DOCUMENT LIST
VOLUME 1 B
MAB IP TURBINE
1. MAB IP Turbine 608W580

Balancing of rotors see MAA / 02
MAA10CT001 Temperature sensor see MAA10CT001
MAA10CT002
2. MAB10HA400 IP - blading (stationary blades) 248W218

3. MAB10HB400 IP - blading (rotating blades) 248W219
4. MAB10HA400 Identification drawing (stationary blades) 248T192
5. MAB10HB400 Identification drawing (rotating blades) 248T196
6. MAB10HA900 Shaft lifting bar 232K224 A
7. MAB10HA710/720 IP gland seal 605W585
8. MAB11AA001 Intercept stop and control valve 612W490

9. MAB11AA001 Intercept stop valve: assembly instructions 612W467
10. MAB11AA001 Intercept stop valve actuator 606W575
11. MAB11CW25 Stop valve actuator cabling
12. MAB11AA01 Reheat control valve actuator 608W985
13. MAB11AA011 Reheat control valve actuator – part list 608W986
14. MAB11AA011 Reheat control valve actuator cabling
MAB11AA061 Insert check valve: RCV-16/ESH-25 see MAA11AA061
MAB11AA501 Directional control valve type: see MAA11AA501
MAB11AU031 Proportional valve type: KFDG4V-5 see MAA11AU031
MAB11AU031 Power amplifier: EEA-PAM-535- D-30-EN5 see MAA11AU031
15. MAB11CG011 Linear transducer: type BTL5 608W990 A
MAB11CG031 Inductive displacement transducer: type see MAA11AU031
MAB11BQ001 Swing arm support see MAA11BQ001
MAB12AA001 Intercept stop and control valve see MAB11AA001

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DOCUMENT LIST
MAB12AA001 Intercept stop valve: assembly instructions see MAB11AA001
MAB12AA001 Intercept stop valve actuator see MAB11AA001
MAB12CW25 Stop valve actuator cabling see MAB11AA001

MAB12AA01 Reheat control valve actuator see MAB11AA001
MAB11AA011 Reheat control valve actuator – part list see MAB11AA011
MAB12AA011 Reheat control valve actuator cabling see MAB12AA001
MAB12AA061 Insert check valve: RCV-16/ESH-25 see MAA11AA061
MAB12AA501 Directional control valve type: see MAA11AA501
MAB12AU031 Proportional valve type: KFDG4V-5 see MAA11AU031
MAB12AU031 Power amplifier: EEA-PAM-535- D-30-EN5 see MAA11AU031
MAB12CG011 Linear transducer: type BTL5 see MAB11CG011
MAB11CG031 Inductive displacement transducer: type see MAA11AU031
MAB12BQ001 Swing arm support see MAA1BQ001

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DOCUMENT LIST
MAC LP TURBINE
01 MAC10 LP turbine 612W468
02 MAC10/CW65 Assembly sealing of LP outer casing 602W233
MAC10/CW71 Balancing of rotors see MAA10/CW71
04 MAC10CP001 Pressure transmitter type:1151AP 606W642

MAC10CP002
MAC10CP003
05 MAC10HA410 Identification drawing (stationary blades SAO) 248T193
06 MAC10HA411 Identification drawing (stationary blades SO) 248T194
07 MAC10HB410 Identification drawing (rotating blades SAO) 248T197
08 MAC10HB411 Identification drawing (rotating blades SO) 248T198
09 MAC10HA420 LP - blading (stationary blades SAO) 248W220
10 MAC10HA421 LP - blading (stationary blades SO) 248W222
11 MAC10HB420 LP - blading (rotating blades SAO) 248W221
12 MAC10HB420 LP - blading (rotating blades SO) 248W223
13 MAC10HA710/720 LP gland seal 606W589
14 MAC10HA911 Shaft lifting bar 233K477 A
15 MAC80AA001 Water injection valve type:ZKV50 606W591
16 MAC10BP010 Atmospheric relief diaphragm TGM 3139/I
17 MAC01 Crossover 211K543 F
18 MAC10AA021 Vacuum breaker valve 612W514


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DOCUMENT LIST
MAD BEARING SUPPORTS
01 MAD/CW51 Bearing data TXMA*M546
02 MAD10 Front bearing pedestal 612W470
03 MAD10BP101 Isolating valve 606W594
04 MAD10HA913 Shaft raising device 606W593
05 MAD11 Journal bearing 606W595
MAD11AA001 Check valve type:RC2 see MAD11
06 MAD20 Thrust bearing pedestal 613W901
MAD20BP101 Isolating valve see MAD10BP101
07 MAD20HA912 Auxiliary bearing 606W590
08 MAD21 Combined journal/thrust bearing 606W597
MAD21AA001 Check valve type:RC2 see MAD11AA001
09 MAD30 Intermediate bearing pedestal 613W902
MAD30HA912 Auxiliary bearing see MAD20HA912
MAD31 Journal bearing see MAD11
MAD40 Low pressure bearing pedestal see MAD30
MAD41 Journal bearing see MAD11


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DOCUMENT LIST
MAK COUPLINGS AND TURNING GEAR
01 MAK21 Expansion sleeve coupling 606W598

MAK31
MAK41
02 MAK80 Turning gear manual BHS manual !
02 MAK80 Turning gear (type: RDV 3 aut I+II ) 233K472 !

03 MAK80 Turning gear manual 612W492 !

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DOCUMENT LIST
VOLUME 2 A
MAV, MAX LUBE OIL, CONTROL AND PROTECTION SYSTEM
1. MAV21AP001 Gear pump 606W830

2. MAV02BB001 Lube oil tank outline TXMAVM511 6
3. Lube oil unit O&M manual COES L070039
4. MAX43 Trip unit S90 606W814
5. MAX44 Sequence valve 606W815
6. MAV22AC001/002 Lube oil cooler outline TXMAVM512 4 !
7. Lube oil cooler GEA O&M manual PHE oper. Manual !
8. MAV91AT001 Lube oil purifier outline TXMAVM513 2
9. Lube oil purifier O&M manual AlfaLaval MMB304_GB

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DOCUMENT LIST
VOLUME 2 B
MAW STEAM SEAL SYSTEM
1. MAW30AC001 Gland steam condenser outline TXMAWM514 4

2. Gland steam condenser manual Casaf 9860709
3. MAW01AA041 Intercept valve 251T939
4. MAW10AA071 Control valve 251T940
5. MAW15AA072 Desuperheater control valve 251T941
6. MAW15AH001 Desuperheater 255T755
7. MAW15AA071 Control valve 251T942
8. Valve serie 1-6911 manual Parcol_1-6911_GB
9. Valve serie 1-6930 manual Parcol_1-6930_GB
10. Packings for Parcol valves manual Parcol Packings
11. Desuperheater manual Parcol 3-4500
12. Pneumatic actuator diaphragm type 1-X-210 Parcol_1-X-210_GB
13. Pneumatic actuator diaphragm type 1-X-250 Parcol_1-X-250_GB
14. Filter Regulator manual SMC IW series
15. Controlfluid valves O&M DT01E-D
16. Controlfluid electric actuator O&M ROTORK IQ_GB

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DOCUMENT LIST
MAL STEAM DRAIN SYSTEM
1. MAL11/12AA461 Drain valve 252T172

2. MAL23/24/25AA461Drain valve 252T173
3. Controlfluid valves O&M see MAW
4. Controlfluid Servovalve O&M L30 PAV_GB
1. LBQ20AA041 Shut-off valves outline 252T219

2. LBD10AA041 Shut-off valves outline 252T221
3. LBQ10AA041 Shut-off valves outline 252T223
4. LBS20AA041 Shut-off valves outline 252T225
5. LBS30AA041 Shut-off valves outline 252T227
6. LBQ20AA061 NR valves outline 252T220
7. LBD10AA061/062 NR valves outline 252T222
8. LBQ10AA061/062 NR valves outline 252T224
9. LBS20AA061 NR valves outline 252T226
10. LBS30AA061 NR valves outline 252T228
11. NR valve manual Bonetti MAN812_I
12. NR valve pneumatic actuator manual Servovalve RPM_GB
13. Shut-off valve manual Bonetti VI1001
14. Shut-off electric actuator manual Rotork:IQ

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DOCUMENT LIST
VOLUME 3
MA STEAM TURBINE PLANT
1. General safety prescriptions 608W542 B

2. Steam turbine general description TXMA*S603 0
3. Steam turbine cross section TXMA*M551 0
4. Steam turbine and auxiliary description TXMA*S518 2
5. Steam turbine start up curves TXMA*S519 2 !
6. Steam turbine operating procedure TXMA*S520 1
7. P&ID Control & protection TXMAXS526 3
8. P&ID Steam seal & drain system TXMAWS524 4
9. P&ID Hydraulic and lube oil system TXMAVS525 5
10. P&ID Supervisory system TXMA*S527 2
11. P&ID Pneumatic air distribuition TXMA*S528 1
12. Steam turbine Instrument & set up list TXMA*S538 7 !
13. Steam turbine Valve list TXMA*S541 3
14. Steam turbine Line list TXMA*S542 3
15. Steam purity requirements for turbine operation TXMA*S522 0
16. Operation with deviation from nominal speed 602W927 A
17. Deviation of steam pressare and temp. from rated values TXMA*S523 0
18. Evaluation of vibrations for turboset 602W935 A
19. Overhaul plans 602W928 0
20. Recommendations for overhauling of steam turbines 605W452 0
21. Conservation of turboset during shutdown TXMA*S548 0
22. Lubricating and control oils for turbine TXMAVS521 0
VOLUME 2B
MAW - STEAM SEAL SYSTEMSYSTEM
ISSUE 05 - 2002
ACA 3501
LIMITATION OF USE
Residual hazards with regard to essential safety requirements of annex I of European pressure equipment directive no. 97/23/EC
If not otherwise specified, the following use limitations

have to be considered for PARCOL control valves, globe 4 – PIPING STRESSES
type body. In general it is not necessary to perform any check and
calculation if pipe size is no larger than 1,5 times valve
0 – MAXIMUM WORKING PRESSURE AND body size (2 times for valve body size up to 3”). As the
TEMPERATURE control valve has not to be used as a fixed point, if inlet
and outlet pipe sizes are different, it should be
Before placing the valve in pipe line make sure that considered the smaller one as it is essential for the
maximum working pressure and temperature are within piping design.
the limits of body rating and lower than allowable
maximum values indicated on valve serial plate.
5 – VIBRATIONS, FATIGUE, etc.
1 – MINIMUM WORKING TEMPERATURE When the control valve is correctly sized and selected
(suitable trim type and sizes of body connections)
Control valves having Carbon Steel body material (SA- significative vibrations caused by the valve itself should
105 or SA216 WCB) are suitable for a minimum working not occur. However on critical services (cavitating or
temperature down to –20°C when working pressure is at flashing liquids), small changes in process conditions
its maximum rating listed value. If working temperature is may cause vibration phenomena even of high intensity
down to –29°C, the maximum pressure must be reduced which can seriously damage trim parts and various
to 1/3 of its maximum rating listed value. Control valves accessories installed on the valve actuator. In this case it
having Cr. Mo. alloy steel body material (SA217 WC6, is necessary to restore the original service conditions, if
SA217 WC9, SA217 C12A, SA182 F11, SA182 F22, SA possible, otherwise the type of trim has to be differently
182 F91, ETC.), particularly suitable for high temperature selected.
services, the minimum working temperature at maximum
rating listed pressure shall be +20°C. It is possible to
reach a minimum working temperature of –29°C but 6 – EROSION, CORROSION
maximum working pressure must be reduced to 1/3 of its 6.1 – Flashing and cavitating liquids
maximum rating listed value at ambient temperature. When flashing or cavitation occur, it is advisable to use
body materials such as Cr. Mo. alloy steel or stainless
RATING Rating pressure
(1)
Pressure at steel, with increased size and rating, with particularly
ANSI bar T ≤ 20°C
(1) (2)
designed trim type.
bar 6.2 – Corrosion
150 20 7 For corrosion purpose PARCOL control valves are
300 51.7 17
designed taking into account an allowance of body wall
600 103.4 34
thickness equal to 2 mm. for casted bodies and 1 mm.
900 155.1 52
for fabricated or forged ones, up to a maximum designed
1500 258.6 86
2500 431 144
wall thickness of 30 mm.
4500 775.7 259 In case of diffused intergranular corrosion it is possible to
(1)
Referring to SA217 WC6/WC9 or SA182 F11/F22 foresee the expected lifetime of valve taking into account
(2)
Also during hydrostatic pressure test at T ≤ 20°C
the increased wall thickness to this purpose. In case of
local corrosion, particularly with chlorides, such as
pitting, interstitial corrosion on gasket seating surfaces
2 – EXPECTED WORKING LIFE IN CREEP RANGE and stress corrosion, it is not possible to make any
When control valves are used at a working temperature realistic prediction of expected lifetime of valve. In these
within the creep range (as listed on the following table), circumstances it is essential to properly select the
the guaranteed expected lifetime is in any case not lower material of valve body.
than 100.000 hours of continuous operation at rating 6.3 – Sulfide stress cracking
listed pressure corresponding to working temperature. In case of services with fluids containing Hydrogen
Sulfide S.S.C. must be considered (refer to NACE
Material Tbeginning MR01-75 norms for materials selection) and all selected
creep materials for valve construction have to be correctly
Carbon steels (i.e.: A216 WCB-A105) 343°C selected.
CrMo steels (i.e.: A217 WC9-A182 F22) 455°C
300 series cast austenitic steels 510°C
6.4 – Fluids containing abrasive solid particles
9% Cr Mo V steels (i.e.: A217 C12A-A182 F91) 538°C The presence of abrasive solid particles into the
300 series forged austenitic steels 538°C controlled fluid is the main cause of trim erosion, in
addition to possible reduction of wall thickness of
pressure containing parts.
3 – SEISMIC STRESSES
PARCOL control valves are designed to withstand a 7 – EXTERNAL FIRE
transversal acceleration up to 0,5 g when equipped with
PARCOL pneumatic actuators of largest allowable size. PARCOL control valves are not designed to withstand
When control valves are equipped with actuators of external fire.
different types and installed in a seismic region, it is
necessary to perform particular checks and calculations.
8 – PROTECTION AGAINST OVERPRESSURES calculate if the maximum given thrust is acceptable to
the supplied valve.
8.1 – Overpressures during safety valves discharge
Control valves must be protected against overpressures
10 – DEAD-END PIPING VALVES
above the maximum allowable rating pressure. Pressure
peaks are allowable, for limited time, during safety valve PARCOL valves are not designed to perform closure in
discharge, up to 10% over the maximum allowable dead-end piping, even they are supplied for on-off
working pressure. service.
8.2 – Water hammer caused by the action of quick
closing valves 11 – CYCLIC LOADS OF PRESSURE AND
Particularly with incompressible fluids it is imperative not TEMPERATURE
to cause the quick closing of valves to avoid hydraulic For most of installations possible cyclic changes of
shock waves which cause uncontrolled overpressure and pressure and/or temperature do not influence the
damages of piping and connected equipment. To this expected lifetime of control valves. The above assuming
regards it has to be avoided the installation of control the following working conditions:
valves with flow to close fluid action, with unbalanced - maximum working temperature not exceeding 550 °C;
plug and with standard pneumatic actuators. - fluid temperature change rate 2 K/min or less;
- cyclic change of working pressure within 1/3 of
9 – ACTUATOR MAXIMUM THRUST maximum allowable rating pressure at corresponding
Any further check it is not necessary when control valves temperature.
are supplied with PARCOL standard pneumatic When working conditions are outside the above
actuators. On other cases it is strictly necessary to specified ones it is necessary a particular check to
calculate the expected lifetime of the valve.
ACA 3507
Issue 06-2005
INSTRUCTION MANUAL
1 - 6930 and 1 - 4430

SERIES
CAGE CONTROL
VALVES
-2-
SAFEGUARDS
GENERAL NOTICES LIFTING AND HANDLING
Beside the rules here below listed the plant man- When lifting use eyebolts, if any, otherwise sling the
ager must meet the regulation in force concerning valve body.
safety and health of workers in jobsites.
WARNING DANGER
Qualified staff only must be used to operate on the
Valve-actuator assembly can be lifted by means
valve.
of eyebolts provided on the actuator, unless oth-
erwise specified in special plates.
The Company rejects any responsibility for personal
injury and damages to equipment imputable to
improper operation, use of non original spare parts
or repairs executed by unauthorised staff.
NOISE
Transportation must be performed utilising original In particular conditions the valve may generate
packing up to job-site. high noise levels. In such cases it is therefore nec-
The Company rejects any responsibility for essary to take the necessary precautions, accord-
damages occurred to things and people due to ing to the regulation in force.
packing because of having been tampered with.
TEMPERATURE
USE AND MAINTENANCE
In case that hot fluids flow through the valve, the
Pay attention to the stem connector and levers operator must pay attention to not insulated parts.
connected to the stem, if any.
Never approach your hands to stem and levers STUFFING BOX

even when the valve is still, unless air supply is cut WARNING DANGER
off and spring is released. Packing must not be released or replaced when
valve is under pressure.
DISASSEMBLY .
WARNING DANGER
To avoid personal injury and damage to the proc-
ess system, isolate the valve from all pressure and
release pressure to the valve body before attempt-
ing also partial disassembling.
WARNING DANGER
To avoid personal injury and damage, isolate the
actuator from all pressure and release pressure be-
fore attempting disassembling connectors.
Stick to instruction manual when disassembling the

actuator, even partially.
-3-
LIMITATION OF USE
If not otherwise specified, the following use limitations

3 – SEISMIC STRESSES
have to be considered for PARCOL control valves, globe
type body. No additional analysis is required, up to acceleration of
1.5 g perpendicular to the actuator axis, when Parcol
0 – MAXIMUM WORKING PRESSURE AND valves equipped with standard pneumatic actuators are
TEMPERATURE installed in seismic areas.
Before placing the valve in pipe line make sure that The 1.5 g value has been calculated, with upward
maximum working pressure and temperature are within oriented actuator, for lowest rating globe valves
the limits of body rating and lower than allowable withstanding most severe process conditions.
maximum values indicated on valve serial plate. For specialty valves, or when different type of actuator is
installed, seismic calculation is performed only where
1 – MINIMUM WORKING TEMPERATURE required.
Control valves having Carbon Steel body material (SA-
4 – PIPING STRESSES
105 or SA216 WCB) are suitable for a minimum working
temperature down to –20°C when working pressure is at In general it is not necessary to perform any check and
its maximum rating listed value. If working temperature is calculation if pipe size is no larger than 1,5 times valve
down to –29°C, the maximum pressure must be reduced body size (2 times for valve body size up to 3”). As the
to 1/3 of its maximum rating listed value. Control valves control valve has not to be used as a fixed point, if inlet
having Cr. Mo. alloy steel body material (SA217 WC6, and outlet pipe sizes are different, it should be
SA217 WC9, SA217 C12A, SA182 F11, SA182 F22, SA considered the smaller one as it is essential for the
182 F91, etc.), particularly suitable for high temperature piping design.
services, the minimum working temperature at maximum
rating listed pressure shall be +20°C. It is possible to 5 – VIBRATIONS, FATIGUE, etc.
reach a minimum working temperature of –29°C but When the control valve is correctly sized and selected
maximum working pressure must be reduced to 1/3 of its (suitable trim type and sizes of body connections)
maximum rating listed value at ambient temperature. significative vibrations caused by the valve itself should
not occur. However on critical services (cavitating or
(1) Pressure at flashing liquids), small changes in process conditions
RATING Rating pressure (1) (2)
T ≤ 20°C may cause vibration phenomena even of high intensity
ANSI bar
bar which can seriously damage trim parts and various
150 20 7
300 51.7 17 accessories installed on the valve actuator. In this case it
600 103.4 34 is necessary to restore the original service conditions, if
900 155.1 52 possible, otherwise the type of trim has to be differently
1500 258.6 86 selected.
2500 431 144
4500 775.7 259
(1)
Referring to SA217 WC6/WC9 or SA182 F11/F22 6 – EROSION, CORROSION
(2)
Also during hydrostatic pressure test at T ≤ 20°C 6.1 – Flashing and cavitating liquids
When flashing or cavitation occur, it is advisable to use
2 – EXPECTED WORKING LIFE IN CREEP RANGE body materials such as Cr. Mo. alloy steel or stainless
When control valves are used at a working temperature steel, with increased size and rating, with particularly
within the creep range (as listed on the following table), designed trim type.
the guaranteed expected lifetime is in any case not lower 6.2 – Corrosion
than 100.000 hours of continuous operation at rating For corrosion purpose PARCOL control valves are
listed pressure corresponding to working temperature. designed taking into account an allowance of body wall
thickness equal to 2 mm. for casted bodies and 1 mm.
Material Tbeginning for fabricated or forged ones, up to a maximum designed
creep wall thickness of 30 mm.
Carbon steels (i.e.: A216 WCB-A105) 343°C
CrMo steels (i.e.: A217 WC9-A182 F22) 455°C
In case of diffused intergranular corrosion it is possible to
300 series cast austenitic steels 510°C foresee the expected lifetime of valve taking into account
9% Cr Mo V steels (i.e.: A217 C12A-A182 F91) 538°C the increased wall thickness to this purpose. In case of
300 series forged austenitic steels 538°C local corrosion, particularly with chlorides, such as
pitting, interstitial corrosion on gasket seating surfaces
and stress corrosion, it is not possible to make any
realistic prediction of expected lifetime of valve. In these
-4-
circumstances it is essential to properly select the 9– ACTUATOR MAXIMUM THRUST
material of valve body. Any further check is not necessary when control valves
6.3 – Sulfide stress cracking are supplied with PARCOL standard pneumatic
In case of services with fluids containing Hydrogen actuators. In other cases it is strictly necessary to
Sulfide S.S.C. must be considered (refer to NACE calculate if the maximum given thrust is acceptable to
MR01-75 norms for materials selection) and all selected the supplied valve.
materials for valve construction have to be correctly
selected. 10 – DEAD-END PIPING VALVES
6.4 – Fluids containing abrasive solid particles PARCOL valves are not designed to perform closure in
The presence of abrasive solid particles into the dead-end piping, even they are supplied for on-off
controlled fluid is the main cause of trim erosion, in service.
addition to possible reduction of wall thickness of
pressure containing parts. 11 – CYCLIC LOADS OF PRESSURE AND
TEMPERATURE
7 – EXTERNAL FIRE For most of installations possible cyclic changes of
PARCOL control valves are not designed to withstand pressure and/or temperature do not influence the
external fire. expected lifetime of control valves. The above assuming
the following working conditions:
8 – PROTECTION AGAINST OVERPRESSURES - maximum working temperature not exceeding 550 °C;
- fluid temperature change rate 2 K/min or less;
8.1 – Overpressures during safety valves discharge
- cyclic change of working pressure within 1/3 of
Control valves must be protected against overpressures
maximum allowable rating pressure at corresponding
above the maximum allowable rating pressure. Pressure
temperature.
peaks are allowable, for limited time, during safety valve When working conditions are outside the above
discharge, up to 10% over the maximum allowable specified ones a particular check is necessary to
working pressure. calculate the expected lifetime of the valve.
8.2 – Water hammer caused by the action of quick
closing valves
Particularly with incompressible fluids it is imperative not
to cause the quick closing of valves to avoid hydraulic
shock waves which cause uncontrolled overpressure and
damages of piping and connected equipment. To this
regards it has to be avoided the installation of control
valves with flow to close fluid action, with unbalanced
plug and with standard pneumatic actuators.
-5-
INSTRUCTION MANUAL
1-6930 and 1-4430 SERIES

CAGE CONTROL VALVES
PREFACE
Before installing 1-6930 and 1-4430 type valves If excessive heating of the body is expected
ascertain that the process operation pressures are not (small valves, on line annealing, MIG welding,
higher than the ones allowable by the valve body rating etc.) and the trim is provided with plastic inserts,
at the design temperature.
Furthermore the valve specific overall rating shall also be the body temperature should be kept under
considered (see general catalogue). The latter may be control. The outside surface temperature should
more restrictive in some instances. not exceed 100°C at
70 ÷ 80 mm distance from the welding bead.
In case of doubt it is better to remove the trim
1 INSTALLATION from valve body before beginning to weld.
1.1 A straight pipe at least 6 DN long must be 1.5 The face-to face dimensions of PARCOL valves
installed in the piping upstream the valve and a are according to IEC 534-3-1 standard, table 1.
further 3 DN length must be installed
downstream. Purpose of the above requirements 1.6 Valves with threaded connections should be
is to avoid stream deviations at body connections, installed with unions to allow their removal.
namely at the inlet one.
Reducers are allowed along above mentioned 1.7 Control valves are normally installed with a by-
straight lengths, provided that they are duly pass to allow their maintenance without shutting
tapered and concentric. down the process.
The need of the by-pass must be stated for each
The more the above requirements are met, the specific application.
more the valve will operate according to the
design pattern, with regard to sizing, as well as to The two shut-off valves located aside the control
noise, plug stability and so on. valve must have the same port as the pipeline,
not to cause considerable head losses when
1.2 Before installing the valve in the line, namely the completely open. The by-pass valve should have
new ones, clean piping and valves from all foreign the same port (full size or reduced) as the control
materials, such as welding chips, scale, oil valve.
grease or dirt.
1.8 1-6930 and 1-4430 series valves are normally
1.3 Check piping connections arrangement for installed in such a way that the flow action tends
dimensions, coaxiality and parallelism, to avoid to open the plug, unless otherwise specified.
tensile and bending stresses, which could occur
when fastening the valve to the piping, namely in 1.9 The flow direction, according to what above
case of valves with flanged connections. specified, is identified by the arrow printed on the
indicating plate.
1.4 If the valve body has butt welding connections the
installation in the pipeline should be done 1.10 Valves are normally installed in vertical position
avoiding to overheat the body wall. with upward oriented actuator.
Anyhow they may be installed and properly
If the valve plug is provided with a plastic seal operate in any other position. Valves should not
insert it is better to lift the plug over the seat when be installed with downward oriented actuator if
welding. the fluid holds solid particles, which may then
build-up into the packing.
-6-
2. VALVE 2.2.1 Pinned version
DISASSEMBLY / REASSEMBLY
2.2.1.1 Remove the pin by pushing it out with a punch.
2.1 VALVE DISASSEMBLY
2.2.1.2 Thoroughly screw the new stem in the plug
2.1.1 Disconnect and remove the valve actuator (see acting on the square end. Do not damage the
actuator instruction manual). ground surfaces.
2.1.2 Unscrew nuts (4) and remove the bonnet with 2.2.1.3 Lay down the guide section of the plug into a
stem and plug. In case that the plug is provided "V" block.
with plastic insert opposing a strong friction or
in case of seizure between plug and cage it is 2.2.1.4 Drill according to the table data driving the tool
better to remove before packing nuts (24) and in the existing hole in the plug.
draw out the bonnet through the stem leaving
the plug in the cage. 2.2.1.5 Remove drill burrs.
2.1.3 To remove the bonnet seal set see the Packing 2.2.1.6 Put some grease on the new pin and slip it into
for Control Valves Manual. the hole.
2.1.4 Remove gasket (8) from the body; sometimes 2.2.1.7 Check stem and plug on a lathe for alignment. If
problems can occur and the gasket can be necessary straighten them with a plastic or
damaged. It is recommended to replace it with rubber hammer.
PARCOL original spares.
2.1.5 To draw out the cage (9) from the body suitable 2.2.2 Not pinned version
threaded holes or grooves are provided; they are
located on the upper side of the cage, which is Proceed like for the pinned version, except for the stem
easily accessible from outside. drilling.
When the valve is supplied with the cage adapter
(11) this one has to be lifted out with the cage. The stem locking is realized by engraving the screw
Should the cage removal get difficult because of thread near to the hole on the plug stem.
scales or build-ups strike gently all around the
upper end.
Figures 1 and 2 – PART LIST
2.1.6 Lift out the seat (6) using the suitable threaded ITEM PART NAME
holes. 1 BODY
If the seal ring (13) is provided pay attention when 2 BONNET
disassembling. 3 STUD BOLT
4 NUT
2.1.7 Remove gasket (14) and seal ring (13), if any. *5 PLUG
*6 SEAT
*7 STEM
2.2 STEM AND PLUG REPLACEMENT
*8 BODY GASKET
*9 CAGE
Even if stem and plug are normally supplied assembled,
nevertheless the connecting procedure of the two parts 11 ADAPTER
should be known, when screw threaded and pinned. * 12 PIN
* 13 GASKET (special construction)
It is recommended to use a new stem (not drilled), while * 14 GASKET
the plug may be reused. * 15 GASKET
It is not possible to cut the threaded end of the stem and 17 PACKING FLANGE
redrill it, because valve stem and actuator stem are not 23 STUD BOLT
long enough to recover the reduction of the length. 24 NUT
27 SET
(*) Suggested spare parts: plug and stem should
be supplied assembled (items 5, 7, 12).
-7-
Figure 1- VERSION WITHOUT ADAPTER
VERSION WITH REGULATING

1-4430 SERIES STEM IN THE SEAT
Figure 2 - VERSION WITH ADAPTER
1-6930 SERIES 1-6930 SERIES
-8-
NOMINAL PIN DIAMETER 2 3 4 5
0 0 0 0
HOLE DIAMETER 2 +0.1
3 +0.1
4 +0.12
5 +0.12
Table 1
2.3 REASSEMBLY Insert cage (9) into the seat. Check the two
pieces for alignment by rotating one on the other.
2.3.1 Clean thoroughly the seating surfaces of the Ensure that the level difference between upper
static gaskets (8), (13), (14) and (15) fitting body surface of the cage and sealing surface of the
with bonnet, body with cage, body with seat and body is included between the minimum and
cage with adapter. maximum values listed in the table 2.
2.3.2 Put the seat gasket (14) into the body. Always 2.3.5 VALVE CONSTRUCTION WITH CAGE
use original spare gaskets as they have ADAPTER (only DN > 6")
calibrated thickness for the correct application. Proceed as per point 2.3.4 inserting also adapter
Incorrect gasket thickness may cause wrong (11) without gasket (15) and checking the
tightening of the cage into the body. sealing surface of the adapter for protrusion.
After check-up remove the adapter, insert gasket
2.3.3 VALVE CONSTRUCTION WITHOUT CAGE (15) and begin to reassemble.
ADAPTER DN < 4"
Insert seat (6) without metal-plastic gasket (8) 2.3.6 Connect stem with plug (see point 2.2) and slip
and seal ring (13), if any. them into the cage. If the plug is provided with
Insert cage (9) into the seat. inserts see supplementary notes at points 4 and
Check the two pieces for alignment by rotating 5.
one on the other.
Ensure that the level difference between upper 2.3.7 Install the bonnet without packing onto the stem.
surface of the cage end the sealing surface of the
body is ≤ 0.1 mm. 2.3.8 Install the entire packing assembling as outlined
Remove cage and seat from the body. in the relevant manual.
Insert gasket (14) and seal ring (13), if provided,
orienting both the lips downward. 2.3.9 Tighten body nuts (4).
Insert seat (6) into the body, taking care of seal Do not exceed the tightening torques listed in the
ring (13), if any. following table 3.
Insert cage (9) into the seat. Check for its
alignment rotating it around the seat ring. 2.3.10 Reinstall the actuator on the bonnet and
reconnect valve stem with actuator shaft.
2.3.4 VALVE CONSTRUCTION WITHOUT CAGE
ADAPTER DN > 6" 2.3.11 Reset the valve.
Insert gasket (14) and seal ring (13), if any.
Insert seat (6) into the body, taking care of seal
ring (13), if any.
Minimum Maximum
RATING
protrusion protrusion
ANSI
mm mm
≤ 600 0.3 0.6
≥ 900 0.5 0.8
Table 2
TIGHTENING OF NUTS item 4

d M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36x3 M39x3
TORQUE
35 50 75 100 140 190 250 360 480 720 825 1050
(Nm)
Table 3
-9-
3 SETTING VALVES WITH PNEUMATIC 3.2.3 Proceed as per point 3.1.3.
DIAPHRAGM ACTUATOR
3.2.4 Increase the air pressure until the plug has
completed the rated travel. Then the pressure
Valves are factory set and supplied complete with test
gauge should indicate 30 psi (plus/minus range
certificate. It is however suggested to further check the
tolerances).
setting before putting the valve in service.
This may be done by means of a pressure gauge and an
3.2.5 See point 3.1.5.
air pressure regulator with output adjustable between 0
and 35 ÷ 40 psi. Connect the pressure regulator inlet
with the air supply line and the outlet with the valve
actuator.
4 REPLACING TEFLON SEAL RING
ON THE PLUG
The pressure gauge measures the pressure in the
actuator. 4.1 PLUG FOR PORT SIZES UP TO 2" (see Fig. 3)
Then proceed as below described for the two cases "air-
to-close" and "air-to-open". 4.1.1 Remove the plug from the valve following the
procedure outlined at points 2.1, 2.1.1, etc.
3.1 VALVES WITH "AIR-TO-CLOSE" 4.1.2 Remove the pin (54) by pushing it out with a
ACTION TYPE 1-X-211 punch.
(reference is made to a 3 ÷ 15 psi setting)
4.1.3 Unscrew the plug from the stem by inserting a
3.1.1 Acting on the pressure regulator increase the screwdriver into the suitable slot at plug head.
pressure on the diaphragm until the plug (5) stops
(against the seat) at the end of its travel. 4.1.4 The teflon seal ring (52) is supplied as a semi-
machined spare part. The sealing surface must
3.1.2 Check that the pressure is 15 psi. Turn if nec- be machined after having fitted the ring on the
essary the spring adjusting screw of actuator until plug.
the requested value is met.
4.1.5 Tighten the plug flange till metal to metal contact.
3.1.3 Check that the travel indicator is in the "0"
position marked on the indicator plate. Displace 4.1.6 Check that stem and plug holes are aligned and
the plate if necessary. slip in the pin (54).
3.1.4 Slowly decrease the air pressure until the travel 4.1.7 Centre the plug in the mandrel of a lathe, without
indicator performs the rated travel. The air damaging the plug stem.
pressure should be 3 psi (plus/minus range
tolerances). 4.1.8 Machine the teflon ring at 45° as shown in the
sketch.
3.1.5 Should the plug travel be shorter than the rated
one check the connection between valve stem
and actuator stem, changing if necessary the
mutual adjustment.
3.2 VALVES WITH "AIR-TO-OPEN"

ACTUATOR TYPE 1-X-212
(reference is made to a 6 ÷ 30 psi setting)
3.2.1 Acting on the pressure regulator increase the

pressure on the diaphragm until the plug begins
to move.
3.2.2 Check that the pressure gauge indicates 6 psi. 4.1.9 Ascertain that the machined surface is even and
Adjust if necessary the spring loading screw and without facets.
the pressure regulator.
4.1.10 Reassemble the valve.
- 10 -
4.2. PLUGS FOR PORT SIZES 3" AND ABOVE 4.2.4 Fit the fastening flange and tighten the screws till
(See Fig. 4) metal to metal contact.
4.2.1 See points 2.1, 2.1.1, etc. 4.2.5 See point 4.1.7.
4.2.2 Remove the screws (55) and the flange (53). 4.2.6 See point 4.1.8.
4.2.3 See point 4.1.4. 4.2.7 See point 4.1.9.
TEFLON SEAL RING FOR SEAT TIGHTNESS 4.2.8 Reassemble the valve.
5 BALANCED PLUGS WITH SEAL

INSERTS (see Fig. 5-6-7-8)
5.1 TEFLON SEAL (see Fig. 5-6)
5.1.1 When the flow through the valve is "bottom entry"

with regard to the plug (standard construction),
the seal ring is fitted on the plug pressed into the
suitable groove with the lips upward oriented (see
Fig. 5).
When the flow through the valve is "top entry"
Figure 3 with regard to the plug (special construction) the
sealing ring is fitted on the plug by means of the
PORT SIZE ≤ 2" (∅ 50)
flange (36), the washers (35) and the screws (34);
in this case the lips of seal ring are downward
oriented (see Fig. 6).
5.1.2 The flange (36) should be oriented in such a way

that the balancing holes on the plug match the
ones on the flange.
5.1.3 Thoroughly tighten the screws (34).
5.1.4 When slipping the flanged plug into the cage ("top
entry" assembly) careful handling is required to
avoid damaging of seal ring.
The upper side of the cage is anyhow machined
with bevelled end to make this operation easier.
Figure 4
PORT SIZE > 3" (∅ 76) 5.2 GRAPHITE SEAL RINGS WITH SPRINGS
(Fig. 7a)
5.2.1 Carefully clean the plug grooves which the seal

Figures 3 and 4 – PART LIST
rings have to be inserted in.
ITEM PART NAME

5.2.2 Insert the two springs with opposite ends starting
5 PLUG STEM from the lower groove.
52 SEAL RING Stretch the spring just the minimum necessary
53 PLUG FLANGE to fit them into the grooves, to avoid any
54 PIN permanent deformation of the outside diameter.
55 SCREW
Recommended spare parts: when possible buy the 5.2.3 Insert first the graphite ring with utmost care into
plug complete with all of its components. the lower groove so that the cut will be located
90° rotated with respect to the spring ones (Fig.
9). Take advantage of the bevel at plug end.
- 11 -
BALANCED PLUGS WITH TEFLON SEAL
Figure 5: STANDARD VERSION Figure 6: SPECIAL VERSION for flow over the plug
ANSI ≤ 600 ANSI ≤ 600 ANSI > 900
PORT SIZE ≥ 2" (∅ 50) PORT SIZE ≥ 4" (∅ 98) PORT SIZE ≥ 2" (∅ 50)
BALANCED PLUGS WITH GRAPHITE SEAL
Figure 7: Shut-off class IV Figure 8: Shut-off class IVS1
Fig. 8b
Fig. 7a Fig. 7b Fig. 8a GRAFOIL RINGS
GRAPHITE RINGS METALLIC RINGS METALLIC RINGS
PORT SIZE 2" PORT SIZE ≥ 3"
Figures 5, 6, 7 and 8 – PART LIST ITEM PART NAME

ITEM PART NAME 38 SEAL RING
5 PLUG 39 SPACER
32 SEAL RING 42 RING NUT
33 FLANGE 43 SEAL RING
34 SCREW 44 SPRING
35 LOCKING WASHER 45 SLIDING RING (PORT SIZE > 12”)
36 FLANGE 48 SEAL RING
37 SEAL RING + B.U. 49 METALLIC RING
Recommended spare parts: when possible buy the plug complete with all of its components
SPRINGS METALLIC RINGS GRAPHITE RINGS
Figure 9
- 12 -
Insert second the upper graphite ring, locating the 5.5 GRAPHITE SEAL RINGS (see Fig. 8b)
cut opposite to the one of the lower ring, always
at 90° with respect to the spring ones. For DN 3" ring nut (42) is welded to the plug (5).
NB: BE CAREFUL WHEN MOUNTING GRAPH-
ITE RINGS: EXCESSIVE DEFORMATIONS MAY 5.5.1 Before replacing the old seal rings with the new
BREAK THEM. ones clean thoroughly the plug grooves from
graphite build-ups.
5.2.4 Carefully centre the two sets of graphite rings + Wash with solvent. Avoid any type of machining,
springs on the plug and slip the assembly into the which may modify the seal housing dimension.
cage, taking advantage of the bevelled cage end.
5.5.2 Fit the first ring spacer (39) into the plug housing,
by pushing it against the shoulder.
5.3 METALLIC SEAL RINGS (see Fig. 7b)
5.5.3 Insert the first graphite seal ring (38) and the
5.3.1 Before replacing the old seal rings with the new second ring spacer (39), then the second seal
ones clean thoroughly the plug grooves. ring (38) and finally the third spacer.
Avoid any type of machining, which may modify
the seal housing dimension. 5.5.4 The ring assembly must be properly adjusted to
fit exactly the inside cage surface without
5.3.2 Stretch the rings (49) just the minimum neces- hindering the plug motion.
sary to fit them into the grooves, to avoid any
permanent deformation of the outside diameter. 5.5.5 Screws (34) should be tightened with the plug
inserted in the cage, in order to exactly centre
5.3.3 Thread seal rings in the plug grooves, starting ring seals and ring spacers on the plug.
from the lower groove and shifting ends of 90°
(see Fig. 9). 5.5.6 Friction thrusts for 1-6930 and 1-4430 series
plugs with graphite seal rings at ambient
temperature and without any lubricant are listed in
5.4 METALLIC SEAL RINGS + GRAPHITE the relevant table. Plug masses are listed as well
(see Fig. 8a) for friction thrust evaluation. For 3" port the ring
pack must be adjusted with the ring nut (42).
5.4.1 Carefully clean the plug grooves which the seal
rings have to be inserted in. 5.5.7 The adjustment has to be done by checking the
inside cage diameter and the outside ring
5.4.2 Insert the seal rings (48) with opposite ends assembly diameter (when mounted on the plug).
starting from the lower groove. Stretch the rings The two diameters should slightly interfer by 0.1 ÷
(49) just the minimum necessary to fit them into 0.2 mm to get the friction thrusts listed in the
the grooves, to avoid any permanent deformation relevant table 4.
of the outside diameter.
5.5.8 To obtain the correct adjustment the lower
5.4.3 Insert the metallic ring (49) with utmost care into surface of the flange (33) or of the ring nut (42)
the lower groove so that the cut will be located should be turned on a lathe. Should it be
90° rotated with respect to the graphite rings ones necessary to reduce the thrust on the ring
(Fig. 9). Then insert rings in the upper groove assembly, machine the external relieve of the
following the same procedure. flange; to increase it machine the internal part
(holes area). Rule of thumb: to increase the
5.4.4 Carefully centre the two sets of graphite rings + external diameter of graphite seal rings by 0.1
metallic rings on the plug and slip the assembly mm a further compression of 0.3 mm about is
into the cage, taking advantage of the bevelled necessary.
cage end.
5.5.9 After the adjustment fold the washer edges (35)
to prevent screw loosening.
For 3" port fasten by tack-welding.
- 13 -
PLUG FRICTION PLUG
DIAMETER THRUST N MASS
mm ± 20% kg
50 80 1.0
76 120 2.5
98 150 4
115 220 10
130 240 15
150 280 18
165 300 25
190 360 35
220 430 60
248 530 75
270 570 90
298 620 110
328 690 165
348 730 190
Table 4
Figure 10
- 14 -
INSTRUCTION MANUAL
VTP VTP 2 VTC2

VTC
PACKINGS
TFG
FOR CONTROL
GRF
VALVES
ISSUE 10 - 1998
INSTRUCTION MANUAL
MANUAL
PACKING FOR 2.2 Remove the bonnet from the valve body, after
having loosened the stuffing nuts to draw out
CONTROL V AL
VALVES
ALVES the stem.
2.3 After having removed packing flange and

FOREWORD packing follower, pull out the ring packing,
generally by using a hook shaped rod.
The packing of a control valve must be carefully Pulling out the graphite rings can be
maintained, because, unlike the case of shut-off particularly difficult; in this case they must
valves, its improper use can affect the valve be broken, paying attention not to scratch
operation. packing box or stem.
As a matter of fact it is not sufficient to take care of
its tightness; it should not cause too much friction 2.4 When all of the rings are pulled out carefully
on the stem either. clean packing box and stem from scales or
Maintenance instructions are therefore a very build-ups. Residuals can be frequently found
important document, because improper replacing on stem and packing box walls, mainly in
or adjustment of packing components may cause case of graphite rings; clean with utmost
the control valve to operate inefficiently. care, not to damage the surfaces, by using if
necessary a liquid detergent (gasoline or
1 REMO VING “SPLIT RING
REMOVING RING”” PACKING
PA trichloroethylene).
1.1 Remove the actuator from the valve. 2.5 Ensure that packing box are not scratched
or scored, before mounting the new packing.
1.2 The rings can be removed from the packing
without dismounting the stem, even if this 3 MOUNTING “SPLIT RING
RING”” PACKING
PA
makes the procedure more difficult and the
(see Fig. 1)
sealing surfaces not thoroughly inspectable
after cleaning.
3.1 Choose the suitable type and size of packing
rings.
WARNING
ARNING::
In case the valve is not removed from the
3.2 Packing rings already shaped and cut,
pipeline remember to release the inside
available as spares ready to use, should be
pressure.
preferably supplied.
1.3 After removing packing flange, packing
3.3 In case the rings must be made out from a
follower and ring spacer, remove the rings
continuous spiral form packing the exact ring
from the packing box by using a spiral puller
length must be defined before starting to cut.
if necessary.
Use a sharp blade inclining it at 45° without
causing the packing to fray.
1.4 Then remove the lantern ring, the other
packing rings and the ring spacer, before
NOTICE
NOTICE
TICE: Never use spiral form packing.
carefully cleaning packing box and stem.
3.4 Insert the bottom ring and begin stuffing the
1.5 Before assembling the new packing check
packing box, ensuring that the first ring
packing box and stem for scoring or
properly lays on the box bottom.
scratches.
For this purpose a suitable ring presser should
In case the stem is scratched replace it with
be used.
a new one.
After having mounted the first ring, place the
others, one by one, without forcing them too
2 REMO VING “FULL RING
REMOVING RING”” PACKING
PA much and staggering each cut by 120°. Insert
the lantern ring in the packing box among
2.1 Remove the actuator off the valve. the rings.
1
Do not tighten too much the new packing:
FIG
FIG.. 1 - SPLIT RINGS during the first operating period it is better
to tolerate a light leakage rather than a stem
jamming due to excessive friction.
After a first fitting period gradually tighten
the nuts in order to eliminate the leakage, if
any, with the minimum friction on the stem.
4 MOUNTING “V -RING
-RING”” P
“V-RING ACKING
PA
(see Fig. 2-3)
4.1 These packing types are built up of shaped

rings, made of pure teflon or loaded teflon,
and finally of bottom rings, to complete the
ring packing.
TFG
4.2 After having mounted bonnet and stem on
the valve insert the spring or the intermediate
bushing (according to the packing type) at
the bottom of the packing box. Then insert
the bottom ring.
4.3 Insert the packing rings, one at a time, with

utmost care, not to jeopardize the tightness;
namely, when the stem thread diameter is
equal or slightly smaller than the ring hole, it
is better to protect it with a soft strip, not to
damage the rings when mounting them.
4.4 Insert the top ring, the ring spacer, if any, then
the packing follower and the packing flange.
TFP
4.5 For packing adjustment see sub-clause 3.5.
4.6 After the adjustment tighten the counternuts,

so that stem vibrations do not modify the
TFG and TFP TYPE PAR
PAR
ARTT LIST packing compression.
I T E M Q .T Y PART NAM E Nuts must be thoroughly tightened for VTP

251 1 SCREW PLUG type only, as the packing compression is
252 1 PACKING FOLLOWER supplied by the the spring.
254 (*) PACKING RING
269 2 RING SPACER 5 MOUNTING “GRAPHITE RING
RING””
272 1 LANTERN RING
PACKING (see Fig. 5)
(*) Packing ring set:
3+5 for stem dia. ≤ 25.4 mm - 2+6 for stem dia. > 25.4 mm 5.1 This packing consists of laminated graphite
rings, separated by intermediate supporting
rings.
5.2 GRFV type packing allows an intermediate

exhaust (LEAK-OFF) connected with the
lantern ring between the two packings.
3.5 After having mounted all of the rings, the
packing follower and the packing flange,
5.3 These packings must be assembled as
begin tightening the nuts alternatively, in
shown in relevant sketches, after having
order to evenly press the packing.
remounted bonnet and stem on the valve.
2
FIG
FIG.. 2 - V-RING P
V-RING ACKING
PA
VTP 2
VTP
VTP TYPE PAR

PART LIST
ART VTP2 TYPE PAR
PART LIST
ART
I T E M Q .T Y PART NAM E I T E M Q .T Y PART NAM E

251 1 SCREW PLUG 251 1 SCREW PLUG
253 1 PACKING FOLLOWER 252 1 PACKING FOLLOWER
260 5 PACKING RINGS 260 (*) PACKING RINGS
261 1 BOTTOM RING 261 1 BOTTOM RING
262 1 SPRING FOR PACKING LOADING 267 1 BOTTOM BUSHING
268 1 TOP RING

7 rings for stem dia. < 41.27 mm
9 rings for stem dia. ≥ 41.27 mm
VTC TYPE P
VTC AR
PAR
ARTT LIST
I T E M Q .T Y PART NAM E
251 1 SCREW PLUG
252 1 PACKING FOLLOWER
263 1 TOP RING
VTC 264 5 PACKING RINGS
265 1 BOTTOM RING
266 1 RING SPACER
267 1 BOTTOM BUSHING
3
FIG
FIG.. 3 - V-RINGS
V-RINGS
VTC 2 VPV
VT
VTCC 2 TYPE PAR
PAR
ARTT LIST VPV TYPE PAR
PAR
ARTT LIST
I T E M Q .T Y PART NAM E I T E M Q .T Y PART NAM E

263 1 TOP RING 260 (*) PACKING RINGS
264 8 PACKING RINGS 261 2 END RINGS
265 1 BOTTOM RING 267 1 BOTTOM BUSHING
267 1 BOTTOM BUSHING 270 1 INTERMEDIATE RING
271 1 RING SPACER
3+4 rings for stem dia.<41.27 - 4+4 rings for stem dia.≥41.27
FIG
FIG.. 4
5.4 When inserting the rings ensure that they
correctly lay down onto each other. Insert them
slowly through the stem, moving the stem after 8
each ring is mounted, to avoid trapping air
9
between the rings. 7
10
5.5 For packing adjustment see point 3.5. 11 6
5.6 After the adjustment tighten the counternuts, 12 2

so that stem vibrations do not modify the
13
packing compression.
14
6 LUBRICATION
UBRICATION
15
PARCOL packings do not generally need any
4 3 1 5
lubricant. A lubricator, such as shown in Fig 4,
is supplied in special cases and where required.
This device, being provided with ball check-val-
ve, allows to lubricate without any backflow
of press-fluid.
4
FIG
FIG.. 5 - GRAPHITE RINGS
GRF GRFV
GRF TYPE PAR

PAR
ARTT LIST GRFV TYPE PAR
PAR
ARTT LIST
I T E M Q .T Y PART NAME I T E M Q .T Y PART NAM E

255 3 PACKING RINGS 255 5 PACKING RINGS
258 1 BUSHING 257 6 RING SPACERS
274 4 RING SPACERS 273 1 LANTERN RING
To inject the grease proceed as follows: 6.5 Open the shut-off valve (7).
6.1 Close the shut-off valve (9). 6.6 Push the grease into the packing by tightening
the screw.
6.2 Remove the screw (1).
6.7 Reclose the shut-off valve.
6.3 Fill in with grease the housing (2) where the
screw is screwed in. Do not inject too much grease to avoid over-
pressure on the packing.
6.4 Remount the screw. Choose the grease type according to the
following table.
Grea se type Old c la ss

ssiifi ca ti on Tem pera tur e li mit s (*) Flu ids
1 A -10+160° WATER AND SLIGHTLY ACID OR BASIC LIQUIDS.
2 C -55+220° STRONG ACIDS AND BASES, FOOD STUFFS.
3 - -15+200° HYDROCARBONS, LUBRICANTS AND SOLVENTS.
4 D -20+400° SAME AS FOR TYPE (1).
5 B -30+280° SAME AS FOR TYPE (1).
(*) Maximum temperatures for grease in continuous service.

For small or not finned bonnets they coincide with the fluid temperature at valve inlet.
5
PARCOL S.p.A. Via Isonzo, 2 - 20010 CANEGRATE (MI) - ITALY
C.C.I.A.A. 554316 - Fiscal code & VAT no. (IT) 00688330158
Telephone: +39 0331 413 111 - Fax: +39 0331 404 215
e-mail: sales@parcol.com - http://www.parcol.com
0294007 Studio Trevisan - Gallarate - Artestampa - Daverio

500 - 10/98 - ACA 3506
ACA 3553
Issue 10-2005
INSTRUCTIONS FOR INSTALLATION - OPERATION - MAINTENANCE

3-4500 SERIES
DESUPERHEATERS
SAFETY INSTRUCTIONS
GENERAL NOTICES
Beside the rules here below listed the plant

manager must meet the regulation in force
concerning safety and health of workers in
jobsites.
Qualified staff only must maintain the valve.

PARCOL rejects any responsibility for damages
occurred to things and people due to improper
use of equipments, use of non original spare parts
or maintenance carried out by unauthorized
personnel.
Use the original package up to the installation site

when handling the valve.
PARCOL rejects any responsibility for damages
occurred to things and people due to packing
because of having been tampered with.
DISASSEMBLY
ATTENTION DANGER
Ensure that steam and water supply have been
cut off before disassembling the equipment
even partially, to avoid damages to things and
people.
Furthermore it is necessary to wait until
surface temperature is under dangerous
values.
INSTRUCTIONS FOR INSTALLATION - OPERATION - MAINTENANCE
3-4500 SERIES DESUPERHEATERS
FOREWORD 2 DISASSEMBLY AND REASSEMBLY
Before installing the desuperheater check that 2.1 DISASSEMBLY

process operating pressure and temperature do
not exceed the body rating. 2.1.1 When the desuperheater is type “A”,
Furthermore the valve specific overall rating shall unfold stop washer (83) and remove
also be considered (see general catalogue). The nozzle (82).
latter may be more restrictive in some instances. When the desuperheater is type “B”,
unfold stop washer (93) and remove
assembly nozzle (90). Nozzle (82) is
1 INSTALLATION welded on (90).
Make sure, mainly in new plants, that upstream 2.2 REASSEMBLY

water piping is clean and free from welding slag.
2.2.1 When the desuperheater is type “A”, lock
nozzle (82) and fold stop washer (83),
otherwise lock assembly nozzle (90) and
fold stop washer (93).
PART LIST
POS. PART NAME
80 BODY
82 NOZZLE
83 STOP WASHER
84 NIPPLE
90 * NOZZLE
93 * STOP WASHER
94 * NOZZLE HOLDER
99 PLATE
100 SCREW
101 PLATE
* For type “B” only
Type “A” Type “B”

ACA 3504
Issue 11-2003
SAFEGUARDS
GENERAL NOTICES USE AND MAINTENANCE
Beside the rules here below listed the plant

manager must meet the regulation in force WARNING DANGER
concerning safety and health of workers in jobsites. Maximum allowable pressure is 6 bar.
Qualified staff only must be used to operate on the To avoid internal parts damage maximum working
valve. pressure is 3.5 bar.
The Company rejects any responsibility for personal
injury and damages to equipment imputable to improper Pay attention to the stem connector and levers
operation, use of non original spare parts or repairs connected to the stem, if any.
executed by unauthorised staff.
Never approach your hands to stem and levers even
Transportation must be performed utilising original when the valve is still, unless air supply is cut off
packing up to job-site. and spring is released.
The Company rejects any responsibility for damages

occurred to things and people due to packing because DISASSEMBLY
of having been tampered with.
WARNING DANGER
Ensure that pneumatic connection are not pressur-
ised before disassembling them.
LIFTING AND HANDLING
When lifting use eyebolts, if any, otherwise sling the

valve body.
Valve-actuator assembly can be lifted by means of

eyebolts provided on the actuator, unless otherwise
specified in special plates.
LIMITATION OF USE
If not otherwise specified, the following use limitations have to The use of any different fluid, with particular reference to
be considered for PARCOL diaphragm pneumatic actuators. dangerous ones, must be outlined on the contractual
documents and approved by Parcol.
0 – MAXIMUM WORKING PRESSURE AND
TEMPERATURE 3 – EXTERNAL FIRE
Before connecting the actuator to the air supply make sure PARCOL pneumatic actuators are not designed to withstand
that the maximum air supply system pressure is lower than external fire.
allowable maximum value PS indicated on actuator data plate.
If not otherwise specified on the actuator plate, the maximum
working temperature is +60°C. 4 – PROTECTION AGAINST OVERPRESSURES
Pressure peaks are allowable, for limited time, during safety
Maximum allowable pressure PS is 6 bar valve discharge, up to 10% over the maximum allowable
working pressure.
1 – MINIMUM WORKING TEMPERATURE 5 –CORROSION

Parcol pneumatic actuators are designed for working PARCOL pneumatic actuators are protected by painting or by
temperatures not lower than the value indicated on material electrolytic zinc coating.
classes and on the actuator serial plate. Standard surface coatings usually guarantee a correct
protection of pressurized parts during the actuator expected
lifetime.
2 – WORKING FLUID
In case of damage of protective coatings on pressurized parts,
Parcol pneumatic actuators are designed and built to work it is necessary to restore them and to verify the pressurized
with air. part wall thickness.
INSTALLATION - OPERATION - MAINTENANCE INSTRUCTIONS
ACA 3545
ISSUE 05-2007
INSTRUCTION MANUAL – USE – MAINTENANCE

1-X-250 SERIES
DIAPHRAGM
ACTUATORS
-2-
SAFEGUARDS
GENERAL NOTICES USE AND MAINTENANCE
Beside the rules here below listed the plant To avoid internal parts damage maximum working
manager must meet the regulation in force pressure is 3.5 bar.
concerning safety and health of workers in
jobsites. Pay attention to the stem connector and levers
connected to the stem, if any.
Qualified staff only must be used to operate on the
valve. Never approach your hands to stem and levers
The Company rejects any responsibility for personal even when the valve is still, unless air supply is cut
injury and damages to equipment imputable to off and spring is released.
improper operation, use of non original spare parts or
repairs executed by unauthorised staff. When an air tank is supplied together with the actuator,
verify that the nominal pressure of the connected
Transportation must be performed utilising original compressed air line is lower than the design pressure
packing up to job-site. reported on the air tank plate.
Otherwise, verify that the maximum flow entering into
The Company rejects any responsibility for damages the air tank is lower than the value reported on the
occurred to things and people due to packing because certificate of the installed safety valve.
of having been tampered with.
DISASSEMBLY

WARNING DANGER
Ensure that pneumatic connection are not pressur-
ised before disassembling them.
LIFTING AND HANDLING
When lifting use eyebolts, if any, otherwise sling the

valve body.
Valve-actuator assembly can be lifted by means of

eyebolts provided on the actuator, unless otherwise
specified in special plates.
-3-
LIMITATION OF USE
3 – EXTERNAL FIRE
If not otherwise specified, the following use limitations PARCOL pneumatic actuators are not designed to
have to be considered for PARCOL diaphragm withstand external fire.
pneumatic actuators.
4 – PROTECTION AGAINST OVERPRESSURES
0 – MAXIMUM WORKING PRESSURE AND
TEMPERATURE Pressure peaks are allowable, for limited time, during
safety valve discharge, up to 10% over the maximum
Before connecting the actuator to the air supply make allowable working pressure.
sure that the maximum air supply system pressure is
lower than allowable maximum value PS indicated on
actuator data plate. 5 –CORROSION
If not otherwise specified on the actuator plate, the PARCOL pneumatic actuators are protected by painting
maximum working temperature is +60°C. or by electrolytic zinc coating.
Standard surface coatings usually guarantee a correct
Maximum allowable pressure PS is 6 bar protection of pressurized parts during the actuator
expected lifetime.
1 – MINIMUM WORKING TEMPERATURE In case of damage of protective coatings on pressurized
parts, it is necessary to restore them and to verify the
Parcol pneumatic actuators are designed for working pressurized part wall thickness.
temperatures not lower than the value indicated on
material classes and on the actuator serial plate.
2 – WORKING FLUID NTG 76/555E02

Parcol pneumatic actuators are designed and built to
work with air.
The use of any different fluid, with particular reference
to dangerous ones, must be outlined on the contractual
documents and approved by Parcol.
-4-
INSTRUCTION MANUAL – USE – MAINTENANCE
1-X-250 SERIES DIAPHRAGM ACTUATOR
1 ACTUATOR INSTALLATION 3 REPLACING THE DIAPHRAGM AIR-TO-

CLOSE ACTION (1-X-251 series)
1.1 The air signal supply of the actuator, or of the
positioner, which it may be supplied with, must be 3.1 Disconnect valve stem from actuator tie rod as
connected with the controller outlet by pipes of per paragraph 2, points 2.1 to 2.6.
copper or other stainless materials. The inside
pipe diameter must not be lower than 4 mm. Bear 3.2 Remove screws (106) of “CASE” (104-105).
in mind that, for valves without positioner, the
higher is the distance between valve and 3.3 Gradually release spring pre-load unscrewing
positioner the higher must be the pipe diameter. alternately screw (112) and removing it.
1.2 “SERTO” quick joints are recommended, which 3.4 Remove top diaphragm case (105) and stem-
allow to connect pipes without welding or diaphragm group. The tie rod is compound of two
threading. parts, connected themselves, that must never be
disconnected.
1.3 Deburr pipe ends and flush pipes by compressed
air before connecting actuator or positioner air 3.5 Remove stem locking dowel (122).
outlet with the controller.
3.6 Straighten the washer (120) edge.
1.4 Finally supply compressed air into the piping and
check any connection for leakage by suds. 3.7 Unscrew clamping nut (121) locking the hub
(117).
1.5 Above mentioned actuators are provided with
standard female ½” NPT threaded connection, 3.8 Replace the diaphragm (118). Before tightening
which may be changed on request. the clamping nut (121) pay attention that the tie
rod (128+129) is completely tightened into the
2 ACTUATOR REMOVAL FROM THE VALVE hub (117).
2.1 Supply compressed air on the diaphragm to 3.9 Lock the clamping nut (121) by folding the
release spring (125) tension on tie rod (128-129). washer (120) edge.
2.2 Mark always the stem connector (302) position 3.10 Reassemble the actuator by reverse procedure.
on adjacent threads to mount it later in the same
position. 4 REPLACING THE DIAPHRAGM AIR-TO-
OPEN ACTION (1-X-252 series)
2.3 Remove screws (303).
4.1 Disconnect valve stem from actuator tie rod as
2.4 Remove stem connector (302). per paragraph 2, points 2.1 to 2.6.
2.5 Release the air pressure on the diaphragm to let 4.2 Remove screws (106-108) from “CASE” (104+104).
the spring return to the maximum extension.
4.3 Gradually release spring pre-load unscrewing
2.6 Disconnect air supply to actuator or positioner, alternately screws (112) and remove them.
when supplied.
4.4 Remove top diaphragm case (104) assembled
2.7 Remove clamping nut (301) (screws for D63 with the housing (100); remove the spring (125)
type). and complete group stem-diaphragm. The tie rod
(128+129) is compound by two parts, connected
2.8 Remove the actuator from the valve using themselves, that must never be disassembled.
eyebolts (111).
4.5 Remove the stem locking dowel (122).
2.9 When manual operator (200) is provided, see
paragraph 9. 4.6 Straighten the washer (120) edge.
4.7 Unscrew clamping nut (121) holding steady the

hub (117).
4.8 Replace the diaphragm (118). Before tightening

the clamping nut (121) pay attention that the tie
rod (128+129) beats on the hub.
4.9 Reassemble the actuator by reverse procedure.
-5-
5 REPLACING THE SPRING FOR AIR-TO- 8.4 Lock again the hand-wheel by fastening the lock
CLOSE ACTUATOR (1-X-251 series) (210) on the relevant support by the suitable
clamp knob (208).
5.1 Disconnect the actuator from the valve as per
paragraph 2, points 2.1 to 2.6. 9 OPERATING THE ACTUATOR PROVIDED
WITH SIDE HAND-WHEEL (CML series)
5.2 Disassemble the actuator as per paragraph 4,
points 4.2 to 4.4. 9.1 To remove the actuator provided with side hand-
wheel, refer to paragraph 2. Make sure that the
5.3 Replace spring (125). above operation is carried out when key (210) is
not inserted and lead screw (213) is in rest
5.4 Reassemble the actuator by reverse procedure. position, i.e. in contact with the manual drive in
the upper part of the yoke.
6 REPLACING THE SPRING FOR AIR-TO-
OPEN ACTUATOR (1-X-252 series) 10 OPERATING ON ACTUATOR WITH SIDE
MANUAL OPERATOR (CML series)
6.1 Disconnect the actuator from the valve as per
paragraph 2, points 2.1 to 2.6. 10.1 Remove the anti-rotation plate (212) from the
lead screw (213) unscrewing screws (211), to
6.2 Remove screws (106-108) of the "CASE" disassemble the manual drive (200) from the
(104+104). yoke (300).
6.3 Remove the lower diaphragm case (104) and 10.2 Unscrew screws (215) to remove manual
housing (100) assembled. operator from the yoke (300) and from the
connector (214).
6.4 Replace the spring (125).
10.3 Hand-wheel symmetric installation (201) on worm
6.5 Reassemble the actuator by reverse procedure. screw manual operator, permits to modify the
sense of rotation of the hand-wheel maintaining
7 ENGAGING THE SIDE MANUAL the same effect of the lead screw (213). This
OPERATOR (CML series) operation must be performed according to points
10.1 and 10.2.
To engage the side manual operator proceed as
follows: 11 USING MANUAL OPERATOR AS
OPENING STROKE LIMIT
7.1 Set free the hand-wheel (201) by removing lock
(209); To use side manual operator as open stroke limit
proceed as follows:
7.2 Turn the hand-wheel to lower the lead screw
(203) and align the screw hole with the groove on 11.1 Remove the key (210).
tie rod (128+129);
11.2 Open the valve to required position.
7.3 Connect lead screw (213) to the tie rod (128-
129) by thoroughly inserting lock (210); 11.3 Move down the lead screw (213) up to it beats
the stem connector (302).
7.4 The operator is now engaged and the valve may
be closed (by turning clockwise the hand-wheel) 11.4 Lock the hand-wheel using the key (210).
or opened.
IN CASE OF DIAPHRAGM PROVIDED WITH
8 DISENGAGING THE SIDE MANUAL HYDRAULIC MANUAL OPERATOR REFER TO THE
OPERATOR (CML series) INSTRUCTION MANUAL coded ACA 3552.
To lock the manual operator proceed as follows: N.B. The action of the diaphragm may be reversed,
using additional spare parts, according to
8.1 Release the actuator spring thrust by acting on INSTRUCTION MANUAL for CHANGE of ACTION
the hand-wheel (201) to set the spring at the (ACA 3557).
maximum extension (lead screw in top position
for air-to-close action, in lower position for air-to-
open action).
8.2 Remove the key (210).
8.3 Turn lead screw (213) to lift it up to the rest

position, i.e. in contact with the manual drive in
the upper part of the yoke (300).
-6-
1-X-252 SERIES DIAPHRAGM ACTUATOR
AIR-TO-OPEN ACTION
120/200 mm MAXIMUM TRAVEL
-7-
1-X-251 MODEL DIAPHRAGM ACTUATOR
AIR-TO-OPEN ACTION
-8-
AIR-TO-OPEN ACTION
PROVIDED WITH SIDE MANUAL OPERATOR
-9-
AIR-TO-CLOSE ACTION PROVIDED WITH SIDE
MANUAL OPERATOR 120/200 mm MAXIMUM
TRAVEL
- 10 -
- 11 -
Edition 2001
Revision D
Installation, operation and

maintenance instructions
Gate, globe and check valves

Doc. DT01e-D
Installation, operation and maintenance instruction
General
Summary
1 GENERAL ....................................................................................................................................... 1.2
2 INSTALLATION .............................................................................................................................. 1.2
3 MAINTENANCE .............................................................................................................................. 1.3
4 PACKING ........................................................................................................................................ 1.4
5 BODY-BONNET BOLTINGS .......................................................................................................... 1.7
6 MAINTENANCE ON BOLTED BONNET GATE VALVE TRIM ..................................................... 1.8
7 MAINTENANCE ON BOLTED BONNET GLOBE VALVE TRIM................................................... 1.9
8 MAINTENANCE ON BOLTED BONNET CHECK VALVE TRIM................................................. 1.11
9 GATE, GLOBE AND CHECK VALVES WELDED BONNET....................................................... 1.13
10 VALVES WITH ELECTRIC/PNEUMATIC ACTUATOR ............................................................... 1.14
11 RECOMMENDATIONS FOR FIELD WELDING........................................................................... 1.16
12 THE NAMEPLATE ........................................................................................................................ 1.19
13 HOW TO ORDER SPARES PARTS............................................................................................. 1.20
14 SAFETY INSTRUCTIONS ............................................................................................................ 1.21
ANNEX A – VALVE’S COMONENTS.......................................................................................................A.1
ANNEX B – RECOMMENDED TORQUE VALUES FOR BOLTING .......................................................B.1
ANNEX C – TEST & WORKING PRESSURE RATING ...........................................................................C.1
ANNEX D – MATERIAL WORKING TEMPERATURE LIMITS................................................................D.1
ANNEX E – MATERIAL CORROSION GUIDE ........................................................................................ E.1
Parts and sentences which have been modified in the last revision of this document are written in
red colour and a vertical line is placed at the right side of them.
Document DT01e- D - Published on: 01 July 2002 Page 1.1

General
1 GENERAL
These instructions apply to all standard valves manufactured by LVF (see
enclosure A and the catalogue for further details).
2 INSTALLATION
2.1 VALVE CARE BEFORE INSTALLATION

LVF valves are carefully made from selected materials to give long, trouble-free
service when properly installed in applications for which they were designed.
Proper care and maintenance in the field can contribute significantly to maximum
performance.
The care the valve receives between the time it is shipped by the manufacturer
and installed in the piping system is important. During this period, the valve can be
handled many times and can be kept in storage for long periods.
Industrial valves are not delicate, but they are mechanical devices which should be
treated as such and handled with care.
LVF always provides valves with appropriate end covers to protect the end
connections and to prevent foreign material from entering the valve. If at all
practical, keep the valves in the original boxes with end covers in place until ready
to be installed. Storing the valves off the ground and indoors is always preferable.
When stored outside, valves should be off the ground and protected by a
weatherproof cover.
Prior to installation, the valves and nameplates should be checked for proper
identification to be sure the valve is the proper type and of a suitable pressure
class (see paragraph 2.3).
Actuate the valve to check for possible damage from shipping and handling. Also,
it is extremely important to inspect the interior of both the valve and the adjoining
pipe for cleanliness. By far the major cause of seat leakage and seat damage is
foreign material in the line.
Also, inspect end connections to be sure that pipe threads and flange faces are
free from scratches, nicks, or dents.
2.2 VALVE IDENTIFICATION

All valves have a nameplate attached that include the figure number, size,
pressure class and material. The valve nameplate needs to be reviewed in
conjunction with the installation, maintenance, and spare parts ordering instruction
in this manual (see also paragraph 13).
Page 1.2 Document DT01e- D - Published on: 01 July 2002

General
2.3 WORKING CONDITIONS
Valves manufactured by LVF are to be installed and assembled on the plant in the
observance of the pressure rating and design temperature and to the test
pressure values.
Moreover limit in the working temperature of the valves shall be observed
according to the rules detailed in paragraph 14.
In order to preserve the packing best performances, LVF valves are, generally,
furnished with the gland bolts loosen. Hence special care is to be placed in the
tightening of gland nuts during installation, in order to get the proper packing
adjustment and functionality (see paragraph 4 for details).
3 MAINTENANCE
3.1 GENERAL
Replacement of important parts as: bodies, bonnets, stems, seats and wedges.
For these pieces is preferable to carry out the replacement in our factory or if
possible in an well equipped workshop.
Maintenance on other parts, more simple to be replaced or checked, as gland

bolts and nuts, body-bonnet bolts and packing can be carried out on site.
In any case, please contact our commercial department giving necessary

information as described in section 13 to obtain correct pieces to be replaced.
After receiving follow closely instructions given in the applicable point of this
manual or contact, for any hesitation, our technical department.
We will not be responsible for any damage due to carelessness on following

instructions.
3.2 ROUTINE INSPECTION AND MAINTENANCE

Once the right valve is properly installed, field maintenance is of a generally
routine nature and can be readily performed by the user.
The critical areas of a valve include the stem threads and those locations where
leakage will most likely occur: the stem packing, the bonnet joint, the seat and the
end connections.
It is desirable that a maintenance program be established which will include
periodic inspection of the noted critical areas.
The most common location of a noticeable leak is at the stem seal. Leakage at the
stem can usually be stopped by adjusting the packing. (see paragraph 4.3).

General
If leakage cannot be stopped by packing adjustment, either installation of

additional packing rings (see paragraph 4.4) or a complete packing replacement
(see paragraphs 4.5 and 4.6) is indicated.
4 PACKING
4.1 OVERVIEW
Special care is to be placed in the tightening of gland nuts during installation or
after replacement of the packing or during periodic checks (remember that due to
natural loss of elasticity of the packing along the time it is possible that tightening is
necessary).
Note, on this argument, that great interest is placed today in fugitive emissions
from piping components (see for example "EPA” American regulation, TA-LUFT
protocol, etc.) in a way that for some places now is compulsory that valve stem
emissions be monitored, being estimated one of the greater causes of atmospheric
emissions from oil, petrochemical and chemical industries.
Our valves are in accordance to the main of the said regulations; however periodic
check for packing adjustment and/or replacement are strongly recommended.
4.2 RECOMMENDATIONS
LVF valves are packed with all-purpose packing sets. This is a combination of
packing using braided rings at the top and bottom of the packing chamber and
flexible graphite packing in the middle section.
Packing glands should be tightened down enough to prevent leakage but not
enough to develop excessive operating torque.
When the gland has advanced approximately to half way into the packing
chamber, it is recommended that additional packing rings be added. To obtain best
results, the stem should be thoroughly cleaned.
Replacement packing should be the same as that originally furnished. LVF valve
packing are inhibited to prevent stem pitting in service.
We recommend packing be purchased from LVF to assure packing with the proper
density and corrosion inhibitors is always used.
4.3 PACKING ADJUSTING

Packing glands should be tightened down enough to prevent leakage but not
enough to develop excessive operating torque.
The packing adjusting is the operation by which the proper compromise is set up. It
consists in loosening and/or tightening the gland bolting, taking in care some easy
tricks:
proceed to lock in a alternative way maintaining the stuffing box flange parallel
to the lid flange.
The stuffing box flange, subject to movements caused by the operator, does
not lead to horizontal or rotary shifting with respect to the lid flange.

General
Every now and then stroke the valve, to allow a correct settlement of the
packing and, in the meantime, to check the effort to operate the handwheel.
Should the operator be convinced that described operations were carried out well
but some leaks arise the packing must be replaced according to the instructions at
paragraphs 4.5 o 4.6.
4.4 ADDING RINGS TO THE PACKING

When the gland has advanced approximately to half way into the packing
chamber, it is recommended that additional packing rings be added.
This shall be carried out in this manner:
1. Remove packing gland bolting and free up packing gland.
2. Remove top ring of packing. This will be a braided graphite packing. Prepare
chamber to accept new ring or rings of packing.
3. Split a number of packing rings of flexible graphite as required and place
individual ring in packing chamber using the gland to ram the packing into the
chamber.
Stagger packing ring’s separations by 90° if more than one ring is required.
Replace top ring of braided graphite packing as required.
4. Tighten packing gland bolting evenly (follow instruction given in paragraph 4.3).
5. Open and close valve to insure free operation and to allow packing settlement.
Check for an acceptable force to operate the handwheel.
6. Place valve back in service.
4.5 RE-PACKING DURING A SHUT DOWN

Long service life from modern graphitic packing requires that adequate loads be
applied when repacking.
Special care is to paid for what follows:
1. All parts should be clean and not scored or pitted, especially the stem.
2. The valve internal parts and bonnet should be assembled prior to installing the
packing.

General
3. Position split packing rings with the ends of adjacent rings rotated 90°.
4. Install in the original sequence. Standard sequence consist of:
Bottom Ring – Braided Ring
Middle Rings – Die formed expanded graphite
Top Ring – Braided Ring
5. Clean the gland bolts.
6. Carefully seat each individual packing ring following indication of points 3 and
4.
7. Apply the recommended torque to the gland nuts evenly without cocking the
gland. See Annex "C" for recommended torques.
8. Tighten the nuts being sure that:
proceed to lock in a alternative way maintaining the stuffing box flange
parallel to the lid flange.
The stuffing box flange, subject to movements caused by the operator,
does not lead to horizontal or rotary shifting with respect to the lid flange.
9. Stroke the valve, then re-check the gland nut torques.
4.6 RE-PACKING THE VALVE UNDER PRESSURE
Back seating the valve and attempting to repack under pressure is hazardous and
is not recommended. Rather than attempting to repack under pressure, it is
preferable to use the backseat to control the stem leakage until a shutdown
provides safe repacking conditions.
When required, re-packing with valve under pressure shall be carried out being
sure that:
1. Proceed opening completely the valve taking care that the stem is brought
back to backseat position.
2. Only when the stem is in this position, loosen the bolts of the stuffing box
flange so to remove pressure from the packing pack.
3. Check that the stem is really in the backseat position ensuring that there are no
losses.
4. Only now loose completely nuts and move the flange and the packing gland
ring upwards. Remove packing and replace with the new one.
5. Position split packing rings with the ends of adjacent rings rotated 90°.
6. Install in the original sequence. Standard sequence consist of:
Bottom Ring – Braided Ring
Middle Rings – Die formed expanded graphite
Top Ring – Braided Ring
7. Carefully seat each individual packing ring following indication of points 5 and
6.

General
8. Bring the packing gland ring and the flange to the original position.
9. Tighten the nuts being sure that:
proceed to lock in a alternative way maintaining the stuffing box flange
parallel to the lid flange.
The stuffing box flange, subject to movements caused by the operator,
does not lead to horizontal or rotary shifting with respect to the lid flange.
5 BODY-BONNET BOLTINGS
Replacement of these bolts does not require special care.
Only proceed to this operation changing one bolt at a time to prevent losses of
pressure on the gasket.
If this is not possible replace the body-bonnet gasket locking bolts in a crossed
way (see figure) till torque are the same of Appendix C.

General
6 MAINTENANCE ON BOLTED BONNET GATE VALVE TRIM
6.1 WEDGE
a) Proceed opening completely the valve taking care that the stem is brought
b) loosen body-bonnet bolting.
c) Remove bonnet and extract wedge (take note of coupling side with respective
seat, see figure ) from the special slot of the stem.
d) Check that no incisions or marks are on holding planes. If any use fine sand
paper or emery cloth to eliminate them, taking care that the original planarity of
these surfaces is not modified.
e) When removed possible defects as described in point d, proceed replacing the
gasket between body and bonnet, insert wedge in the slot of the stem making
sure that is in the same previous couplement with surface of seats (see figure
here below).
f) Proceed tightening body-bonnet bolts as described in section 5.
IMPORTANT: final situation (couplement with faces of seats) will be the same that
before disassembling, being this couplement of faces obtained, during first
assembling, by expanding the seats with the wedge in the operating position. In
case that operator doesn't follow these instructions WE CANNOT GUARANTEE
the absence of leakage: the customer is advised about the necessity to perform
again the seat test according to the original test specification.
6.2 STEM
c) Remove bonnet-stem group (wedge must remain in his position) and then
disassemble the stem turning it in anticlockwise way.
d) Make sure that surfaces of the stem (especially the ones in contact with
packing) are not damaged. If you are not in this optimal situation contact our
commercial department giving information as described later to obtain a new
stem and replace screwing it clockwise in the bonnet yoke sleeve.

General
e) Replace body-bonnet gasket.
f) Insert the slot of the stem into the wedge, bring the bonnet to his original
position and tighten body-bonnet bolts as described in section 5.
6.3 SEATS
No maintenance is possible on seats of gate valves but only replacement with the
aid of blunt chisels and hammer after removal of bonnet and wedge (see figure),
and new seats must be assembled by expansion
Note that seats to be used for this operation, if possible, can be greater in external
diameter than the original ones (due to original expansion). In this case please
advise the housing diameter into the body to our commercial department in order
to obtain the proper seats for replacement.
Being this replacement very difficult to be performed in non-equipped workshops, it
is preferable to be carried out in our factory where this procedure will be completed
by a new set of hydrostatic tests.
7 MAINTENANCE ON BOLTED BONNET GLOBE VALVE TRIM
7.1 DISC
LVF’s globe valves do not allow the disc to be disassembled from stem.

General
To check seal characteristics between disc and seat we suggest the "BLUEING
TEST":
c) Remove bonnet with stem and disc attached and put some prussic-blue on
surface of the seat.
d) Place the bonnet-stem-wedge group in the original position and tighten bolts as
described in section 5.
e) Take the valve in close position, wait 20 seconds min., and repeat points a and
b.
f) Remove bonnet again and check that blue trace on wedge is uniformly present
on contact surface. If this is not happened there are two possibilities:
there are incisions or marks on holding planes. Check and, if any, use fine
sand paper or emery cloth to eliminate them, taking care that the original
planarity of these surfaces is not modified.
no repair is possible because of the great damage. Contact our
commercial department giving details as described later to receive a new
group stem-wedge and replace it removing the handwheel and turning it
in clockwise way so that can leave the bonnet. Assemble the new one in
anticlockwise way to the bonnet and put again the handwheel in the
original position.
g) Replace the body-bonnet gasket.
h) Reassemble the group bonnet-stem-wedge and close bolts as described in
section 5.
7.2 STEM

General
c) Remove bonnet with stem and wedge attached.
d) Make sure that surfaces of the stem (especially the ones in contact with
packing) are not damaged. If you are not in this optimal situation contact our
commercial department giving information as described later to obtain a new
stem-wedge group and replace screwing it anticlockwise in the bonnet yoke
sleeve.
e) Replace body-bonnet gasket.
Reassemble the group bonnet-stem-wedge and close bolts as described in
section 5.
7.3 SEAT
Check the seat in the same way as described in point 8.1 (blueing test , points a to
e).
f) Then remove bonnet again and check that blue trace on seat is uniformly
present on contact surface with the wedge and that no damage has occurred. If
you are not in this situation, we suggest to contact our commercial department
giving details as described later to receive a new seat and replace removing
the old one turning it in anticlockwise way with a proper hexagon ring wrench
so that it can leave the body. Assemble the new one in clockwise way to the
body .
g) Replace the body-bonnet gasket.
h) Reassemble the group bonnet-stem-wedge and close bolts as described in
section 5.
8 MAINTENANCE ON BOLTED BONNET CHECK VALVE TRIM

There are three types of check valves : ball, piston and swing type.

General
8.1 BALL AND PISTON

a) Disassemble the valve.
b) Visual check all contact surfaces.
c) No incisions or marks must be on holding planes. If any AND ONLY FOR
PISTON use emery cloth to eliminate them, taking care that the original
planarity of the surface is not modified.
d) Except for pistons as described in point c, if some damage are present contact
our commercial department giving details as described later to receive a new
wedge and replace it.
e) Replace the body-bonnet gasket.
f) Reassemble the valve and close bolts as described in section 5.
8.2 SEAT OF BALL OR PISTON VALVES

b) Visual check all contact surface of the seat.
c) No incisions or marks must be on holding planes. If there are damages, we
suggest to contact our commercial department giving details as described later
to receive a new seat and replace removing the old one turning it in
anticlockwise way with a proper hexagon ring wrench (see figure in point 8.3)
so that it can leave the body. Assemble the new one in clockwise way to the
body .
d) Replace the body-bonnet gasket.
Reassemble the group bonnet-wedge and close bolts as described in section 5.
8.3 SWING TYPE VALVE

b) Visual check all contact surface of the swing wedge.
c) No incisions or marks must be on holding plane. If there are proceed with the
aid of a hinge pin extractor to disassemble the swing from the bonnet. If
possible use fine sand paper or emery cloth to eliminate them, taking care that
the original planarity of the surface is not modified. If result is not satisfactory
contact our commercial department giving details as described later to receive
a new one. Replace the old loosening the nut and then fix the hinge again to
the bonnet using the pin.
d) Replace the body-bonnet gasket.
e) Reassemble the group bonnet-wedge and close bolts as described in section
5.

General
8.4 SEAT FOR SWING TYPE VALVES

As per gate valves no maintenance is possible on the seat, but only replacement
as described in section 7.3.
9 GATE, GLOBE AND CHECK VALVES WELDED BONNET

The only one difference with respect to the above mentioned cases is that there is
a seal weld between body and bonnet.
So no complete maintenance is for this case programmed. Is only possible a

replacement of the packing and tightening of gland bolting as described for bolted
bonnet valves.
But for special maintenance (not under our responsibility if not performed in our
factory) is possible to remove the seal welding with machining and then,
unscrewing the bonnet, proceed as per bolted bonnet valves .
After maintenance and reassembling a new seal weld is necessary (welding
procedures are available).

General
10 VALVES WITH ELECTRIC/PNEUMATIC ACTUATOR

Valves provided or prearranged to be connected to electric and/or pneumatic
actuators present the same constructive solutions of the different models (globe,
trim), of the valves with manual command. The differences are in fact limited to
the presence of an automatic actuator as a substitute of the handwheel.
Therefore this solution allows favourable conditions both about the availability of
spare parts, and for the maintenance point of view: it is to be noticed, in fact, than
all the maintenance operations described in the above paragraphs cover also the
valve with automatic actuator.
For installation, maintenance and normal use regarding strictly the actuators, see
the installation manuals supplied with them and making integral part of this
document.

General
10.1 COUPLING VALVE ACTUATOR.

Valves supplied with simple predisposition to connection by actuators, are realised
for getting an optimal junction between the two elements; the efficiency of this link
depends, in any case, on the connection flange mounted on the actuator: make
sure to match all the requirements indicated in data sheet supplied with the valve
and here below summarised:
Actuator’s run
Vertical push
Torsion moment
The lack of observance of the data sheet requirements relieves LVF S.p.A. for any
responsibility on correct behaviour of the valves.
In case of valves supplied with actuators, their substitution shall be done only after
the LVF S.p.A.’s verification; the lack of observance of this indication relieves LVF
S.p.A. for any responsibility on correct behaviour of the valves.

General
11 RECOMMENDATIONS FOR FIELD WELDING
11.1 OVERVIEW
Welding activities are special processes: codes to carry out these activities are
usually referenced (see paragraph 11.2) as well as Procedure specifications
(WPS) and Qualifications (PQR).
The aim of paragraph 11 is, however, to furnish general indication to support the
selection of the process to adopt, and to provide auxiliary information to the ones
which are stated into a typical WPS.
11.2 EVALUATION OF CODE REQUIREMENTS

Prior to welding, construction code requirements should be reviewed (ASME
Section I, VIII, IX, ANSI B31.1, B31.3, etc.). Applicable code requirements may
supersede these recommendations.
In the absence of specific code requirements, the guidelines of ASME Section IX
are recommended for qualification.
11.3 SELECTION OF PROCESS

Based on the size of the valve and the skill of the welder, either the SMAW (stick)
or GTAW (Tig) process is recommended. SMAW is generally preferred, although,
GTAW offers more control (at the expense of speed) and may be preferred for ¾”
and smaller valves.
11.4 SELECTION OF WELD FILLER METAL

For SMAW, use 3/32” electrode on the first pass with 1/8” for subsequent passes.
1/8” and 5/32” electrodes may be used effectively on larger valves. 3/32” type is
recommended for GTAW. 1/16” and 1/8” may also be used successfully.
Care should be taken to use only SMAW electrodes that have been kept
essentially free of exposure to moisture. Exposure of coated electrodes to moisture
can cause high levels of hydrogen in the weld which can result in delayed
cracking, especially with hardenable alloys.
To avoid such a risk follow carefully the electrode supplier instructions. When no
instruction is available, the following guidelines can help:
Electrodes should be kept in heated electrode ovens operating at 120÷150 °C
when not being used.
Limit atmospheric exposure to 8 hours maximum without reheating.
Electrodes may be used immediately following opening of the hermetically
sealed containers in which they are normally supplied.

General
11.5 SELECTING THE WELDER
Most construction codes require a welder to qualify prior to making a production
weld.
Welder performance qualification provides some assurance that the production
weld will be of good quality since the welder has proven, through testing, that he
can make a good weld. Care should be taken in comparing the welder’s
qualification with the code requirements to assure that the welder has qualified
with an appropriate test for the intended production weld.
11.6 JOINT CLEANLINESS

The area in-way-of welding should be cleaned to remove, dirt, oil, and protective
coatings.
This should be done prior to fit-up or residue in the joint overlap will not be
removed.
Sanding, grinding, or wire brushing is usually adequate. Solvents may be
necessary, if oil is to be removed.
11.7 FIT-UP (SOCKET WELD VALVES)
To avoid fracture, bottom out the pipe engagement into the socket and pull it back
approximately 1,5 mm to allow for weld shrinkage. Tack welds should be
contoured to allow for easy inclusion into the final weld.
11.8 WELDING TECHNIQUE

Prior to welding, the valve should be lightly closed. Where possible, attach the
electrical ground to the adjoining pipe on the same side of the valve as the
weld being made. Do not attach the ground to the handwheel or upper
structure of the valve or arcing across the valve seating surfaces could occur.
Where possible, welding should be done in the flat or horizontal position.
Where vertical welding is necessary, progression should be upward (vertical
down welding is prone to lack-of-fusion).
A minimum preheat of 150÷180 °C is recommended for alloy steels
A low heat input is preferred as far as allowed by the applicable welding
procedure specification.

General
A minimum of two layers should be used for all socket welds. This will
decrease the chance of leaking even if one pass contains a weld defect.
Due to controls on thickness and chemical composition, post weld heat
treatment (PWHT) on LVF steel valves is normally rarely required. However
always refer to applicable governing codes to determine if post weld heat
treatment is required.
When required, it shall be carried out a localised PWHT. In this manner LVF
valve’s dimensions normally allow the packing to withstand without damage a
not extremely high PWHT temperature. In any case check the packing
capability to seal after PWHT and, if the case, replace it (see paragraph 4.5).

General
12 THE NAMEPLATE
Each single valve made by LVF is equipped with an identification nameplate,
placed over the handwheel. Original nameplates are printed up by a customised
laser machine to prevent any possibility of counterfeit or imitation.
The nameplate shows several descriptive data, the reference to the applicable
design code and the working condition/limits.
The following figure shows, in the legend, the meaning of each single data.
1 2
3 9
4 10
5 11
6 12
7 13
8 14
1. Since July 2001 our nameplates bear the CE marking, which means that the
valves comply with the safety requirements of European Directive 97/23/EC –
PED. The Directive allows the CE logo to be applied ONLY for valves OVER
ONE INCH. No logo can be shown in the other sizes.
2. TAG or Customer’s identification code
3. LVF Valve’s catalogue figure
4. Shell material (body, bonnet, extension…)
5. Stem material
6. Closure member material (in case of hard-facing overlay “HF” will be shown)
7. Seat material (in case of hard-facing overlay “HF” will be shown)
8. LVF job and item number
9. Nominal diameter
10. Valve’s typology
11. Valve’s Pressure rating
12. Ambient temperature (requested by ANSI/ASME B16.34): this is the
temperature which the maximum working pressure (point 13) is referred to
13. Maximum working pressure referred to the ambient temperature (point 12)
14. Applicable Design codes

General
13 HOW TO ORDER SPARES PARTS
Genuine spare parts and accessories authorized by LVF serve to maintain safety
and efficiency. The use of non-authorized parts may lead to personnel injury or
damage to parts, and render the warranty void.
Genuine replacement parts are available for LVF current standard valves and can
usually be shipped from stock. All parts are made with the same careful inspection
and laboratory control given original valves and parts.
To obtain spare parts please contact our commercial department indicating the
LVF job and item number.
The LVF job and item number are shown on the identification nameplate set on the
handwheel (see paragraph 12) and allow us to provide all the information related
both to the valve and to the spare parts.

General
14 SAFETY INSTRUCTIONS
This paragraph details the essential safety requirements to be taken in care by the
user, according to the Annex 1 of the European Directive 97/23/CE (P.E.D.).
Moreover the temperature of the valves in the operating conditions shall be
maintained within the limits stated by the further paragraphs.
14.1 REFERENCE DOCUMENTS

European Directive 97/23/EC - PED: Pressure Equipment Devices
LVF Procedure SQ 27: Particular material appraisal according to 97/23/EC – PED
14.2 RISK ANALYSIS

Each single sentence written in bolt characters refer to a general safety note.
Otherwise a reference to the proper page of this manual is provided.
RISK PREVENTIVE ACTION

Accidental contact with 1) Check periodically the tightness of the bolted
dangerous service medium connections (connection flanges, body bonnet –
(toxic fluids, high or low flange etc.) – see paragraphs 3.2, and 5
temperature fluids, 2) Check periodically the tightness of the packing bolts
corrosive fluids, etc.) due to – see paragraphs 3.2, and 4.3
a gasket or packing blow 3) Replace periodically gasket and packing – see
out paragraphs 3.2, 4.4 and 4.5
4) Replace immediately gasket and packing after a
blow out- see paragraph 4.6
5) Use always protective clothing (masks, gloves,
etc.) during all maintenance operations
6) Predispose supplementary safety protection
devices on the bolted connections
7) Use only suitable and approved materials for
gaskets and packing
8) Avoid absolutely overpressures in the closed
cavities due to the "boiler effect”, installing
apposite relief devices
Accidental contact with 1) Depressurise completely the valve before all the
dangerous service medium operations
(toxic fluids, high or low 2) Open and close the valve and check the internal
temperature fluids, pressure that should be equal to external
corrosive fluids, etc.) during ambient pressure before to disassembly the
the disassembly or valve.
maintenance operations 3) Empty and drain completely the valve before to
disassemble it
4) Drain the remaining fluid with suitable devices
5) Vent the valve when disassembled

General
6) Use always protective clothing (masks, gloves,

etc.) during all maintenance operations
Accidental contact with 1) Check periodically the valve body for corrosion
dangerous service medium damages (pitting holes, corrosion cracks etc.)
(toxic fluids, high or low
temperature fluids,
corrosive fluids, etc.) due to
a leakage from valve body
Structural yielding of valve 1) Use the valves only in the prescribed pressure /
body with consequent risk temperature limits – see paragraph 2.3, 14.5
of contact with dangerous 2) Consider the suitability of the material in respect with
fluids (corrosive fluids, high the service Medium – see Annex E.
or low temperature fluids, 3) Check periodically the valve body thickness for
etc.) or explosion or fire. erosion or corrosion processes
4) Predispose supplementary devices to avoid
additional forces on the valve body
5) Avoids absolutely water hammers: install
apposite devices if necessary (brakes, anti –
shock devices, pressure reducing devices, etc.)
6) Avoid to submit the valve to excessive vibrations
7) Avoid quick pressure and / or temperature
changes
8) Avoid absolutely overpressures in the closed
cavities due to the "boiler effect" installing (if
necessary) apposite relief devices
Accidental contact with 1) Use always protective clothes (gloves, etc.)
high or low temperature during the manoeuvre and maintenance
parts operations
2) Predispose apposite insulation on the valve
3) Predispose apposite warnings about the risks of
burns
4) For cryogenic service use only valves provided
with cryogenic extension.
Fire or explosion in case of 1) Install only EEX proof electrical devices in the
service with flammable area
fluids 2) Check periodically the tightness of the bolted
connections (connection flanges, body bonnet –
flange etc.) – see paragraphs 3.2, and 5
3) Check periodically the tightness of the packing bolts
– see paragraphs 3.2, and 4.3
4) Replace periodically gasket and packing – see
paragraphs 3.2, 4.4 and 4.5
5) During maintenance operation shut down all
electrical device s in the area.
6) Don't smoke and don't use any portable not EEX-

General
proof electrical device in the area.

7) Drain and vent completely the valve before to
proceed with the maintenance operations
Explosion in case of 1) Install and use only valves completely degreased
oxygen service 2) Don't grease any component of the valve
3) use valves only made with materials suitable for
oxygen services (see EN 1797-1).
4) Install only EEX proof electrical devices in the
area
5) Check periodically the tightness of the bolted
connections (connection flanges, body bonnet –
flange etc.) – see paragraphs 3.2, and 5
6) Check periodically the tightness of the packing bolts
– see paragraphs 3.2, and 4.3
7) Replace periodically gasket and packing – see
paragraphs 3.2, 4.4 and 4.5
8) During maintenance operation shut down all
electrical device s in the area.
9) Don't smoke and don't use any portable not EEX-
proof electrical device in the area.
14.3 OTHER INSTRUCTIONS

Here below are provided some further instructions related to the safe use of LVF
valves, as outlined by the European Directive 97/23/EC – PED.
Special consideration is given to the temperature/pressure limits in the working
condition as depending by the design code (e.g. ASME, Din, BSI…) as well as by
the additional safety requirements outlined by 97/23/EC Directive (PED).
Moreover additional suggestions are given to provide the end user with a guideline
for the selection of the materials depending on the medium/service foreseen.
14.4 VALVE CLASSIFICATION ACCORDING TO PED

LVF has implemented, operates and maintains a quality system as described in
the PED Annex III Module H.
When not otherwise stated LVF valves are designed, manufactured and tested to
comply with Category III and for fluid groups 1 and 2.
According to the requirements in PED Annex II the LVF valves are marked with the
CE logo as follow:
Valves from ¼” up to 1”: No CE marking is allowed
Valves above 1”: CE marking on the nameplates
Details regarding the method of CE marking for valves above 1” are given in
paragraph 12.

General
14.5 PRECAUTIONS BEFORE INSTALLATION

Prior to the installation, the valves and nameplates should be checked for proper
identification to be sure the valve is the proper type and of a suitable pressure
class.
Valves manufactured by LVF are to be installed and assembled on the plant in the
observance of the pressure rating and design temperature and to the test
pressures. Do not use valve with pressure higher than the working values
stated in Annex B.
Additional attention is to be paid to the limits in the working temperature, which
belong from the body/bonnet material according to the Annex D.
Annex B shows the test & working pressure values for the most common
materials; these values, as well as ones adopted for the not listed materials,
comply with the main international standards API 598, ANSI/ASME B16.34, MSS-
SP 61...
14.6 MATERIAL MECHANICAL REQUIREMENTS

In addition to the requirements of each specific design code adopted, according to
the PED – Appendix I, paragraph 7.5, “[…] a steel is considered as sufficiently
ductile […] if, in a tensile test carried out by a standard procedure, its elongation
after rupture is no less than 14 % and its bending rupture energy measured on an
ISO V test-piece is no less than 27 J, at a temperature not greater than 20°C but
not higher than the lowest scheduled operating temperature […]”.
LVF approval, achieved through module “H”, is based on a specific procedure for
the Particular Material Appraisal (PMA): this procedure is aimed to verify (when no
other approval is available for a material) in a statistical way, that the combination
of the material/supplier is able to match the above requirements.
Such a procedure, agreed with the Notified Body, is based on mechanical tests
and provide results in enough quantity to feel the material sufficiently ductile,
according to the PED requirements.
14.7 LVF APPROVED MATERIALS

Appendix A shown a list of the main materials approved by LVF, according both to
the PMA procedure and to the other internal qualification methods. The list is
aimed to provide the end-user instruction about the approved main materials and
their lower limit in the working temperature.
The end user is advised that misapplication of the product may result in injuries or
property damage. A selection of valve components of the proper material
consistent with the particular performance requirement, is important for proper
application.
Examples of the misapplication or misuse of the valves include use in an
application in which the pressure/temperature rating is exceeded or failure to
maintain valves as recommended.

Annex A – Valve’s Components
ANNEX A – VALVE’S COMONENTS
Gate valves
Globe valves
Document DT01e- D - Published on: 01 July 2002 Page A.1

Annex A – Valve’s Components
Piston and ball check valves
Swing check valves
Page A.2 Document DT01e- D - Published on: 01 July 2002

Annex B – Test & Working Pressure Rating
ANNEX B
TEST PRESSURE RATING
Document DT01e- D - Published on: 01 July 2002 Page B.1

WORKING PRESSURE RATING
A105N (note 1, 2) - LF2 (note 2)

Temp. STANDARD CLASS SPECIAL CLASS
°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 19 51 102 135 153 255 425 766 19 51 103 137 155 258 430 775
93 17 46 93 124 139 232 387 697 19 51 103 137 155 258 430 775
148 15 45 90 120 135 226 377 678 19 51 103 137 155 258 430 775
204 13 43 87 116 131 218 364 655 19 51 103 137 155 258 430 775
260 11 41 82 109 123 206 344 619 19 51 103 137 155 258 430 775
315 9 37 75 100 113 188 314 566 18 49 98 131 147 245 409 737
343 8 36 74 98 111 185 308 555 18 48 96 128 144 240 401 722
371 7 36 73 97 110 183 306 550 18 47 95 127 143 239 398 717
398 6 34 69 92 104 173 289 521 16 43 86 115 130 217 361 651
426 5 28 56 75 85 142 236 425 13 35 71 94 106 177 295 531
454 4 18 36 49 55 92 153 276 8 23 46 61 69 115 192 345
482 3 11 23 31 35 59 98 177 5 14 29 39 44 73 123 221
510 2 7 14 18 21 35 59 106 3 8 17 23 26 44 73 133
537 1 3 7 9 10 17 29 53 1 4 8 11 13 22 36 66
LF3 (note 3)
°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 19 51 103 137 155 258 430 775 19 51 103 137 155 258 430 775
93 17 51 103 137 155 258 430 775 19 51 103 137 155 258 430 775
148 15 50 100 133 150 250 418 753 19 51 103 137 155 258 430 775
204 13 48 97 129 145 243 405 729 19 51 103 137 155 258 430 775
260 11 45 91 122 137 229 381 687 19 51 103 137 155 258 430 775
315 9 41 83 111 125 208 347 625 19 51 103 137 155 258 430 775
343 8 40 81 107 121 202 338 608 19 51 103 137 155 258 430 775
371 7 39 78 104 117 195 326 587 18 48 98 130 147 245 408 735
398 6 34 69 92 104 173 289 521 16 43 86 115 130 217 361 651
426 5 28 56 75 85 142 236 425 13 35 71 94 106 177 295 531
454 4 18 36 49 55 92 153 276 8 23 46 61 69 115 192 345
482 3 11 23 31 35 59 98 177 5 14 29 39 44 73 123 221
510 2 7 14 18 21 35 59 106 3 8 17 23 26 44 73 133
537 1 3 7 9 10 17 29 53 1 4 8 11 13 22 36 66
Page B.2 Document DT01e- D - Published on: 01 July 2002

F1 (note 4)
°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 18 47 95 127 143 239 398 718 18 47 95 127 143 239 398 718
93 17 46 93 124 140 234 390 702 18 47 95 127 143 239 398 718
148 15 45 89 119 134 224 374 674 18 47 95 127 143 239 398 718
204 13 44 88 117 132 220 367 661 18 47 95 127 143 239 398 718
260 11 42 85 114 128 214 357 642 18 47 95 127 143 239 398 718
315 9 41 83 111 125 208 347 625 18 47 95 127 143 239 398 718
343 8 40 81 107 121 202 338 608 18 47 95 127 143 239 398 718
371 7 39 78 104 117 195 326 587 18 47 95 127 143 239 398 718
398 6 36 73 97 109 183 305 549 18 47 95 127 143 239 398 718
426 5 35 69 93 105 175 291 524 18 47 95 127 143 239 398 718
454 4 33 67 89 100 167 279 503 17 46 93 124 139 229 389 700
482 3 31 62 82 93 154 258 464 15 40 81 107 121 202 337 607
510 2 19 38 51 58 96 161 290 9 24 48 64 72 121 202 363
537 1 11 22 30 34 56 94 170 5 14 28 37 42 71 118 212
F11 Cl. 2 (note 5)

°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 19 51 103 137 155 258 430 775 19 51 103 137 155 258 430 775
93 17 51 103 137 155 258 430 775 19 51 103 137 155 258 430 775
148 15 49 99 132 149 248 414 746 19 51 103 137 155 258 430 775
204 13 47 95 127 143 238 398 717 19 51 103 137 155 258 430 775
260 11 45 91 122 137 229 381 687 19 51 103 137 155 258 430 775
315 9 41 83 111 125 208 347 625 19 51 103 137 155 258 430 775
343 8 40 81 107 121 202 338 608 19 51 103 137 155 258 430 775
371 7 39 78 104 117 195 326 587 19 50 101 134 151 252 421 758
398 6 36 73 97 109 183 305 549 19 50 100 133 150 251 418 753
426 5 35 69 93 105 175 291 524 18 49 99 132 148 248 413 744
454 4 33 67 89 100 167 279 503 17 46 93 124 139 233 389 700
482 3 31 62 82 93 154 258 464 15 40 81 107 121 202 337 607
510 2 22 44 58 65 109 183 329 10 27 54 73 82 137 228 412
537 1 14 29 39 44 74 124 223 7 18 37 49 55 93 155 279
565 1 9 19 26 29 49 82 148 4 12 24 32 37 62 103 186
593 1 6 13 17 19 33 55 99 3 8 16 22 24 41 68 124
621 1 4 8 11 12 21 35 63 2 5 10 14 15 26 44 79
648 1 2 5 6 7 13 21 38 1 3 6 8 9 16 27 48
For welding end valves only. Flanged end ratings terminate at 565°C

F22 Cl.3 (note 5)
°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 19 51 103 137 155 258 430 775 19 51 103 137 155 258 430 775
93 17 51 103 137 155 258 430 775 19 51 103 137 155 258 430 775
148 15 50 100 133 150 250 418 753 19 51 102 136 153 255 426 766
204 13 48 97 129 145 243 405 729 19 49 99 133 149 249 416 749
260 11 45 91 122 137 229 381 687 18 49 99 132 148 248 413 744
315 9 41 83 111 125 208 347 625 18 49 99 132 148 248 413 744
343 8 40 81 107 121 202 338 608 18 49 98 131 147 246 411 740
371 7 39 78 104 117 195 326 587 18 48 98 130 147 245 408 735
398 6 36 73 97 109 183 305 549 18 47 95 126 142 237 396 713
426 5 35 69 93 105 175 291 524 17 46 92 123 139 232 386 696
454 4 33 67 89 100 167 279 503 16 44 88 118 133 221 369 664
482 3 31 62 82 93 154 258 464 15 41 82 110 124 206 344 620
510 2 25 52 69 77 129 216 390 12 32 65 86 97 162 270 487
537 1 17 35 47 53 89 149 269 8 22 44 59 67 112 187 336
565 1 12 24 32 36 60 100 180 5 15 29 39 45 75 125 226
593 1 7 15 19 22 37 63 113 3 9 18 25 28 47 78 141
621 1 4 9 12 14 23 39 71 2 5 11 15 17 29 49 88
648 1 2 5 7 8 14 23 42 1 3 7 9 10 17 29 53
F5
°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 19 51 103 137 155 258 430 775 19 51 103 137 155 258 430 775
93 17 51 102 136 154 256 427 770 19 51 103 137 155 258 430 775
148 15 49 98 131 148 246 411 740 19 50 100 133 150 251 418 753
204 13 48 97 129 145 243 405 729 18 49 99 132 148 248 413 744
260 11 45 91 122 137 229 381 687 18 49 99 132 148 248 413 744
315 9 41 83 111 125 208 347 625 18 48 97 129 146 243 406 731
343 8 40 81 107 121 202 338 608 18 48 96 128 144 240 401 722
371 7 39 78 104 117 195 326 587 18 47 94 125 141 236 394 709
398 6 36 72 96 109 182 303 546 17 45 91 121 136 227 379 682
426 5 35 69 93 105 175 291 524 16 44 87 117 132 220 366 660
454 4 33 66 88 99 166 277 499 15 41 83 111 125 208 347 625
482 3 25 51 67 76 127 212 383 12 32 63 85 95 159 265 478
510 2 18 37 50 56 94 157 283 8 23 47 63 71 118 196 354
537 1 13 27 36 41 68 114 205 6 17 34 45 51 85 142 257
565 1 9 19 26 29 49 82 148 4 12 24 33 37 62 103 186
593 1 6 13 18 20 34 57 102 3 8 17 22 25 42 71 128
621 1 4 8 11 12 21 35 63 2 5 10 14 15 26 44 79
648 1 2 4 6 7 11 19 35 1 3 5 7 8 14 24 44

F9
°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 19 51 103 137 155 258 430 775 19 51 103 137 155 258 430 775
93 17 51 103 137 155 258 430 775 19 51 103 137 155 258 430 775
148 15 50 100 133 150 250 418 753 19 51 103 137 155 258 430 775
204 13 48 97 129 145 243 405 729 19 51 103 137 155 258 430 775
260 11 45 91 122 137 229 381 687 19 51 103 137 155 258 430 775
315 9 41 83 111 125 208 347 625 19 51 103 137 155 258 430 775
343 8 40 81 107 121 202 338 608 19 51 103 137 155 258 430 775
371 7 39 78 104 117 195 326 587 19 50 101 134 151 252 421 758
398 6 36 73 97 109 183 305 549 19 50 100 133 150 251 418 753
426 5 35 69 93 105 175 291 524 18 49 99 132 148 248 413 744
454 4 33 67 89 100 167 279 503 17 46 93 124 139 233 389 700
482 3 31 62 82 93 154 258 464 15 41 82 110 124 206 344 620
510 2 25 52 69 77 129 216 389 12 32 65 86 97 162 270 487
537 1 17 34 46 52 87 145 262 8 21 43 58 65 109 182 327
565 1 11 23 31 35 58 98 177 5 14 29 39 44 73 123 221
593 1 7 15 20 23 38 65 116 3 9 19 25 29 48 81 146
621 1 5 10 13 15 25 43 77 2 6 13 17 19 32 54 97
648 1 3 7 9 10 17 29 53 1 4 8 11 13 22 36 66
F91
°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 19 51 103 137 155 258 430 775 19 51 103 137 155 258 430 775
93 17 51 103 137 155 258 430 775 19 51 103 137 155 258 430 775
148 15 50 100 133 150 250 418 753 19 51 103 137 155 258 430 775
204 13 48 97 129 145 243 405 729 19 51 103 137 155 258 430 775
260 11 45 91 122 137 229 381 687 19 51 103 137 155 258 430 775
315 9 41 83 111 125 208 347 625 19 51 103 137 155 258 430 775
343 8 40 81 107 121 202 338 608 19 51 103 137 155 258 430 775
371 7 39 78 104 117 195 326 587 19 50 101 134 151 252 421 758
398 6 36 73 97 109 183 305 549 19 50 100 133 150 251 418 753
426 5 35 69 93 105 175 291 524 18 49 99 132 148 248 413 744
454 4 33 67 89 100 167 279 503 17 46 93 124 139 233 389 700
482 3 31 62 82 93 154 258 464 15 41 82 110 124 206 344 620
510 2 26 52 70 79 133 222 399 12 32 65 86 97 162 270 487
537 1 25 49 66 75 125 208 375 11 28 57 77 86 145 241 435
565 1 24 49 66 74 124 206 372 11 28 57 77 86 145 241 435
593 1 20 41 55 62 104 173 311 9 25 52 69 77 129 216 389
621 1 15 30 41 46 76 127 230 7 19 38 51 57 96 159 288
648 1 9 19 26 29 49 82 148 4 12 24 33 37 62 103 186

F304 (note 6) - F304H
°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 18 49 99 132 148 248 413 744 19 51 103 137 155 258 430 775
93 15 41 82 110 124 206 344 620 17 46 92 122 138 230 384 691
148 14 37 74 99 111 186 310 558 15 41 82 110 124 206 344 620
204 13 34 68 91 102 171 285 513 14 38 76 101 114 190 317 571
260 11 32 64 85 96 160 267 481 13 35 71 95 107 178 297 536
315 9 29 60 80 90 150 250 451 12 33 67 89 101 168 280 504
343 8 29 59 78 88 148 246 444 12 33 66 88 99 165 275 495
371 7 29 58 77 87 146 244 439 12 32 65 86 97 162 270 487
398 6 28 57 76 85 143 238 429 12 32 63 85 95 159 265 478
426 5 27 55 74 83 138 231 417 12 31 62 82 93 155 258 465
454 4 27 54 72 82 136 227 409 11 30 61 81 91 152 253 456
482 3 26 53 71 80 134 223 401 11 29 59 79 89 149 248 447
510 2 26 52 69 78 131 219 394 11 29 58 77 87 146 243 438
537 1 22 44 58 66 110 184 331 10 27 56 74 84 140 234 420
565 1 21 42 56 63 106 177 319 10 26 53 70 79 133 221 398
593 1 17 35 47 53 88 147 265 8 22 44 58 66 110 184 332
621 1 13 27 36 41 68 114 205 6 17 34 45 51 85 142 257
648 1 10 21 28 32 53 88 159 5 13 26 35 39 66 110 199
676 1 7 15 20 23 38 65 116 3 9 19 25 29 48 81 146
704 1 5 11 15 17 29 49 88 2 7 14 19 22 36 61 110
732 1 4 8 11 12 21 35 63 2 5 10 14 15 26 44 79
760 1 3 6 8 9 16 27 49 1 4 8 11 12 20 34 62
787 1 2 4 6 7 11 19 35 1 3 5 7 8 14 24 44
815 0 1 3 4 5 9 15 28 1 2 4 6 7 11 19 35
F316 (note 6) - F316H
°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 18 49 99 132 148 248 413 744 19 51 103 137 155 258 430 775
93 16 42 85 113 128 213 355 640 18 47 95 126 142 237 396 713
148 14 38 77 102 115 192 321 578 16 43 86 114 128 215 358 645
204 13 35 70 94 106 177 295 531 15 39 78 104 117 196 327 589
260 11 33 65 87 98 164 274 494 14 36 73 97 109 183 305 549
315 9 31 62 82 93 155 259 466 13 34 69 92 104 173 289 520
343 8 30 61 81 91 153 255 459 13 34 67 90 102 169 283 509
371 7 29 59 79 89 149 249 449 12 33 66 88 100 166 278 500
398 6 29 58 78 88 147 245 441 12 32 65 87 98 164 273 491
426 5 28 58 77 87 145 242 436 12 32 65 86 97 162 270 487
454 4 28 57 76 86 144 239 431 12 32 64 85 96 160 267 481
482 3 28 57 76 85 143 238 429 12 32 63 85 95 159 265 478
510 2 26 53 71 79 133 222 399 12 31 63 84 94 157 263 473
537 1 24 48 64 72 120 200 361 11 28 57 77 86 145 241 435
565 1 23 47 63 71 118 197 355 11 28 57 77 86 145 241 435
593 1 21 42 55 63 105 175 315 9 26 52 69 78 131 219 394
621 1 16 32 43 48 81 135 244 7 20 40 54 61 102 169 305
648 1 12 25 33 38 63 106 191 6 15 32 42 47 79 133 239
676 1 9 20 26 30 50 84 152 4 12 25 33 38 63 105 190
704 1 7 16 21 24 40 66 120 3 9 19 26 29 50 83 150
732 1 6 13 17 19 33 55 99 3 8 16 22 24 41 68 124
760 1 5 10 13 15 26 43 77 2 6 13 17 19 32 54 97
787 1 4 7 10 12 19 33 60 2 5 9 13 15 25 42 75
815 1 2 5 7 8 14 23 42 1 3 4 8 10 17 29 53

F304L (note 7) - F316L
°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 15 41 82 110 124 206 344 620 17 46 92 122 138 230 384 691
93 13 34 69 93 104 174 290 523 14 38 77 103 116 194 324 584
148 12 31 62 83 93 156 260 469 13 34 69 93 104 174 290 522
204 11 28 56 75 85 142 237 426 12 31 63 84 95 158 264 476
260 9 26 52 69 78 131 219 394 11 29 58 78 88 146 244 440
315 9 24 49 66 74 124 206 372 10 27 55 73 83 138 230 415
343 8 24 48 64 72 120 201 362 10 26 53 71 80 134 224 403
371 7 23 47 63 71 118 197 355 9 26 52 69 78 131 219 394
398 6 23 46 61 69 115 193 347 9 25 51 68 77 128 214 385
426 5 22 45 60 67 113 188 339 9 25 50 67 75 126 210 379
454 4 22 44 58 66 111 184 332 9 24 49 65 74 123 206 371
F321 (note 8) - F321H

°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 18 49 99 132 148 248 413 744 19 51 103 137 155 258 430 775
93 16 44 88 118 133 222 370 667 17 46 94 125 140 234 391 704
148 15 41 82 109 123 205 341 615 9 42 83 111 125 209 349 629
204 13 37 76 101 114 190 317 570 14 38 76 101 114 190 317 571
260 11 35 71 94 106 177 295 531 13 35 71 94 106 177 295 531
315 9 33 67 89 100 167 279 504 12 33 67 89 101 168 280 505
343 8 33 65 87 98 164 274 494 12 33 66 88 99 165 275 496
371 7 32 64 85 96 160 267 481 12 32 65 86 97 162 270 487
398 6 31 63 84 94 157 263 474 12 32 64 85 96 160 268 482
426 5 31 62 82 93 155 259 466 12 32 63 85 95 159 265 478
454 4 30 61 82 92 153 256 461 12 31 63 84 94 158 263 474
482 3 30 61 81 91 152 253 456 12 31 62 83 94 156 260 469
510 2 26 53 71 79 133 222 399 12 31 62 83 94 156 260 469
537 1 24 49 65 73 123 204 368 11 28 57 77 86 145 241 435
565 1 21 43 57 64 107 179 323 10 27 56 74 84 140 234 420
593 1 18 37 49 56 93 156 280 9 24 48 64 73 122 203 365
621 1 16 32 43 48 81 135 244 7 20 40 54 61 102 169 305
648 1 12 25 33 38 63 106 191 6 15 32 42 47 79 133 239
676 1 9 19 25 28 48 80 145 4 12 24 32 36 60 101 181
704 1 7 15 19 22 37 63 113 3 9 18 25 28 47 78 141
732 1 5 11 15 17 29 49 88 2 7 14 19 22 36 61 110
760 1 4 8 11 13 22 37 67 2 5 11 14 16 27 46 84
787 1 3 7 9 10 17 29 53 1 4 8 11 13 22 36 66
815 1 2 5 6 7 13 21 38 1 3 6 8 9 16 27 48

F347 (note 8) - F347H
°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 18 49 99 132 148 248 413 744 19 51 103 137 155 258 430 775
93 17 45 91 121 136 227 379 682 18 49 98 131 147 246 411 740
148 15 42 84 113 127 211 353 635 17 45 90 120 135 226 376 678
204 13 39 78 105 118 197 329 593 16 42 85 113 127 212 354 638
260 11 37 74 99 111 186 310 558 15 41 82 109 123 205 342 616
315 9 35 70 94 106 177 295 531 15 39 78 105 118 197 329 592
343 8 34 69 92 104 173 289 521 14 38 77 103 116 194 323 581
371 7 34 68 91 102 170 284 511 14 37 76 101 114 190 317 570
398 6 33 67 90 101 169 282 508 14 37 75 100 113 189 315 567
426 5 33 67 89 100 167 279 504 14 37 75 99 112 187 312 562
454 4 33 66 88 100 167 278 501 14 37 74 99 112 186 310 559
482 3 31 62 82 93 154 258 464 14 37 74 98 111 185 309 556
510 2 26 53 71 79 133 222 399 12 32 65 86 97 162 270 487
537 1 25 49 66 75 125 208 375 11 28 57 77 86 145 241 435
565 1 24 49 66 74 124 206 372 11 28 57 77 86 145 241 435
593 1 22 44 58 66 111 185 302 10 27 55 74 83 138 231 416
621 1 18 37 50 56 94 157 283 8 23 47 63 71 118 196 354
648 1 11 23 31 35 58 98 177 5 14 29 39 44 73 123 221
676 1 8 16 22 25 42 71 127 4 10 21 28 32 53 88 159
704 1 6 12 16 19 32 53 95 3 7 15 21 23 39 66 119
732 1 4 9 12 14 23 39 71 2 5 11 15 17 29 49 88
760 1 3 7 9 11 18 31 56 1 4 9 12 14 23 39 71
787 1 2 5 7 8 14 23 42 1 3 7 9 10 17 29 53
815 1 2 4 6 7 11 19 35 1 3 5 7 8 14 24 44
F44 - F51 (note 9) - F53 (note 9)

°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 19 51 103 137 155 258 430 775 19 51 103 137 155 258 430 775
93 17 49 99 132 148 248 413 744 19 51 103 137 155 258 430 775
148 15 45 91 122 137 222 381 687 19 51 102 136 153 255 426 767
204 13 42 84 113 127 211 353 635 18 47 94 125 141 236 394 709
260 11 39 79 105 119 198 330 595 16 44 88 118 133 221 369 664
315 9 38 76 102 115 192 319 575 16 42 85 114 128 214 357 642
343 8 37 75 101 113 189 315 568 16 42 84 112 126 211 352 634
371 7 37 74 99 112 186 311 560 15 41 83 111 125 208 347 626
398 6 36 73 97 109 183 305 549 15 41 82 109 123 205 343 617

N08020: Alloy 20
°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 19 51 103 137 155 258 430 775 19 51 103 137 155 258 430 775
93 17 49 99 132 148 248 413 744 19 51 103 137 155 258 430 775
148 15 49 98 131 147 245 409 737 19 51 103 137 155 258 430 775
204 13 46 92 123 139 232 386 696 19 51 103 137 155 258 430 775
260 11 45 90 120 135 225 376 677 19 50 101 134 151 252 420 756
315 9 41 83 111 125 208 347 625 18 48 96 129 145 242 404 727
343 8 40 81 107 121 202 338 608 18 48 96 128 144 240 401 722
371 7 39 78 104 117 195 326 587 18 47 95 127 143 239 399 718
398 6 36 73 97 109 183 305 549 17 47 94 125 141 235 392 706
426 5 35 69 93 105 175 291 524 17 46 93 124 139 232 387 698
N04400: Monel 400

°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 15 41 82 110 124 206 344 620 17 46 92 123 138 230 384 692
93 13 36 72 96 109 182 303 546 15 40 81 108 122 203 338 609
148 13 34 68 91 102 170 284 511 14 37 75 101 113 189 316 569
204 12 33 65 87 98 164 274 494 14 36 73 97 110 183 306 551
260 11 32 65 87 98 163 273 491 14 36 73 97 109 182 304 548
315 9 32 65 87 98 163 273 491 14 36 73 97 109 182 304 548
343 8 32 65 87 98 163 273 491 14 36 73 97 109 182 304 548
371 7 32 65 87 98 163 273 491 14 36 73 97 109 182 304 548
398 6 32 64 85 96 161 268 484 13 35 72 95 107 179 300 540
426 5 31 63 84 94 157 263 474 13 35 70 94 105 176 294 529
454 4 23 46 62 70 116 195 350 11 30 61 81 91 152 254 457
482 3 16 34 45 51 85 141 255 8 22 44 58 66 110 184 332

N06600:Inconel 600
°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 19 51 103 137 155 258 430 775 19 51 103 137 155 258 430 775
93 17 51 103 137 155 258 430 775 19 51 103 137 155 258 430 775
148 15 50 100 133 150 250 418 753 19 51 103 137 155 258 430 775
204 13 48 97 129 145 243 405 729 19 51 103 137 155 258 430 775
260 11 45 91 122 137 229 381 687 19 51 103 137 155 258 430 775
315 9 41 83 111 125 208 347 625 19 51 103 137 154 257 429 772
343 8 40 81 107 121 202 338 608 19 50 101 134 151 253 421 759
371 7 39 78 104 117 195 326 587 18 49 99 132 149 249 415 748
398 6 36 73 97 109 183 305 549 18 48 97 130 146 244 407 733
426 5 35 69 93 105 175 291 524 18 48 96 128 144 240 401 722
454 4 33 67 89 100 167 279 503 17 46 93 124 139 233 389 700
482 3 31 62 82 93 154 258 464 15 41 82 110 124 206 344 620
510 2 22 45 59 67 112 187 338 11 29 58 78 88 146 244 440
537 1 14 29 39 44 74 124 223 7 19 38 51 58 96 161 290
565 1 71 19 25 28 47 79 143 4 12 24 33 37 62 103 186
593 1 6 12 16 19 32 53 95 3 8 16 22 24 41 69 124
621 1 4 9 12 14 23 38 70 2 6 12 16 18 30 50 91
648 1 4 8 11 12 21 35 63 2 5 11 14 16 27 46 83
N08800: Incoloy 800
°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 18 49 99 132 148 248 413 744 19 51 103 137 155 258 430 775
93 17 45 91 121 137 228 380 684 19 51 102 135 153 254 424 775
148 15 43 86 114 128 215 358 645 18 47 96 127 144 239 400 764
204 13 41 82 110 124 206 34 620 17 46 92 123 138 230 384 720
260 11 39 79 106 119 199 332 611 16 44 88 118 133 222 370 692
315 9 39 78 105 118 197 329 593 16 44 88 117 132 220 367 667
343 8 39 78 104 117 196 326 588 16 43 87 116 131 218 364 662
371 7 38 77 103 116 194 324 583 16 43 86 115 130 216 361 656
398 6 36 73 97 109 183 305 549 16 43 86 114 128 215 358 650
426 5 34 69 93 104 174 291 524 16 42 84 113 127 212 354 645
454 4 33 67 89 100 167 279 503 16 42 84 113 127 212 353 637
482 3 31 62 82 93 154 258 464 15 41 82 110 124 206 344 635
510 2 26 53 71 79 133 222 399 12 32 65 86 97 162 270 620
537 1 25 49 66 75 125 208 375 11 28 57 77 86 145 241 487
565 1 24 49 66 74 124 206 372 11 28 57 77 86 145 241 435
593 1 22 44 58 66 111 185 333 10 27 55 74 83 138 231 435
621 1 18 37 50 56 94 157 283 8 23 47 63 71 118 197 416
648 1 14 27 37 42 70 116 210 6 17 35 47 53 88 147 354
676 1 8 17 23 26 44 74 134 4 11 23 30 34 58 96 266
704 1 4 8 11 12 21 35 63 2 5 11 14 16 27 46 174
732 1 3 6 8 10 16 28 51 1 4 8 11 13 22 36 82
760 1 2 4 6 6 11 19 35 1 3 6 8 9 15 25 66
787 0 2 4 5 6 10 17 32 1 2 5 7 8 13 23 45
815 0 1 3 4 5 8 14 25 0 2 4 5 6 11 18 33

N06625: Inconel 625 (note 10) - N08825: Incoloy 825 (note 8) - N10276: Hastelloy C-276 (note 11)
°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 19 51 103 137 155 258 430 775 19 51 103 137 155 258 430 775
93 17 51 103 137 155 258 430 775 19 51 103 137 155 258 430 775
148 15 50 100 133 150 250 418 753 19 51 103 137 155 258 430 775
204 13 48 97 129 145 243 405 729 19 51 103 137 155 258 430 775
260 11 45 91 122 137 229 381 687 19 51 102 136 153 255 426 767
315 9 41 83 111 125 208 347 625 18 49 99 132 149 249 415 748
343 8 40 81 107 121 202 338 608 18 48 97 130 146 244 407 733
371 7 39 78 104 117 195 326 587 18 47 96 127 144 239 400 720
398 6 36 73 97 109 183 305 549 18 47 95 126 143 238 397 714
426 5 35 69 93 105 175 291 524 18 46 94 125 141 236 394 709
454 4 33 67 89 100 167 279 503 17 41 93 124 139 232 387 698
482 3 31 62 82 93 154 258 464 15 32 82 110 124 206 344 620
510 2 26 53 71 79 133 222 399 12 28 65 86 97 162 270 487
537 1 25 49 66 75 125 208 375 11 28 57 77 86 145 241 435
565 1 24 49 66 74 124 206 372 11 27 57 77 86 145 241 435
593 1 22 44 58 66 111 185 333 10 27 55 74 83 138 231 416
621 1 18 37 50 56 94 157 283 8 23 47 63 71 118 197 354
648 1 12 25 33 38 63 106 191 6 16 33 44 49 83 138 249
676 1 9 20 26 30 50 84 151 5 13 26 35 39 65 109 197
704 1 7 14 19 22 37 62 111 3 9 19 25 28 48 80 145
F904L
°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 16 44 88 117 132 220 368 662 18 49 98 131 147 246 410 739
93 15 41 82 110 124 207 345 621 17 46 92 123 138 231 385 693
148 14 37 74 99 112 187 312 562 16 41 83 111 125 209 348 627
204 13 34 68 91 102 171 285 513 14 38 76 102 114 190 318 573
260 11 31 63 83 94 157 262 472 13 35 70 93 105 175 293 527
315 9 29 59 79 89 148 248 446 12 33 66 88 99 166 277 498
343 8 28 57 77 87 145 242 435 12 32 64 86 97 162 269 486
371 7 28 56 75 84 141 235 424 12 31 63 84 94 157 263 473

N08810: Incoloy 810

°C 150 300 600 800 900 1500 2500 4500 150 300 600 800 900 1500 2500 4500
37 15 41 82 110 124 206 344 620 17 46 92 123 138 230 384 692
93 14 37 74 99 111 186 310 558 15 41 83 110 124 207 346 623
148 13 34 69 93 104 174 290 523 14 38 77 89 96 194 324 584
204 12 33 66 88 99 165 275 496 14 36 73 84 89 184 307 553
260 11 31 62 83 94 157 262 471 13 35 70 93 105 175 292 526
315 9 30 60 80 91 151 252 454 13 33 67 89 101 168 281 507
343 8 29 58 77 87 146 244 439 12 32 65 86 97 163 272 490
371 7 28 57 77 86 144 241 434 12 32 64 86 96 161 269 484
398 6 28 56 75 85 142 237 426 12 31 63 84 95 158 264 476
426 5 28 56 74 84 140 234 421 12 31 62 83 94 156 261 470
454 4 27 54 73 82 137 228 411 11 30 61 81 92 153 255 459
482 3 27 54 72 82 136 227 409 11 30 61 81 91 152 254 457
510 2 26 53 71 79 133 222 399 11 29 59 79 89 149 249 448
537 1 25 49 66 75 125 208 375 11 28 57 77 86 145 241 435
565 1 22 44 59 67 112 186 336 11 28 57 77 86 145 241 435
593 1 22 44 58 66 110 184 331 10 27 55 74 83 138 231 416
621 1 18 37 50 56 94 157 283 8 23 47 63 71 118 197 354
648 1 14 28 37 42 71 118 212 6 17 35 47 53 88 147 266
676 1 12 25 33 37 62 104 187 6 15 31 41 46 78 130 235
704 1 9 18 25 28 47 78 142 4 11 23 31 35 59 98 177
732 1 7 14 18 21 35 59 106 3 8 17 23 26 44 73 133
760 1 5 10 13 15 26 43 77 2 6 13 12 12 32 54 97
787 0 4 7 10 12 19 33 60 2 5 9 13 15 25 42 75
815 0 2 5 7 8 14 23 42 1 3 7 9 10 17 29 53
Notes:
1 Upon prolonged exposure to temperatures above 426°C the carbide phase of steel may be
converted to graphite. Permissible, but not recommended for prolonged use above 426°C.
2 Only killed steel shall be used above 454°C.
3 Not to be used above 343°C.
4 Upon prolonged exposure to temperatures above 468°C the carbide phase of carbon-
molybdenum steel may be converted to graphite. Permissible, but not recommended for
prolonged use above 468°C.
5 Permissible, but not recommended above 593°C.
6 At temperatures over 537°C, use only when carbon content is 0.04% or higher.
7 Not to be used over 426°C.
9 This steel may become brittle after service at moderately elevated temperatures. Not to be
used over 315°C.
10 Not to be used over 648°C. Alloy N06625 in the annealed condition is subject to severe loss of
impact strength at room temperatures after exposure in the range of 537-760 °C.

Annex C – Recommended torque values for bolting
ANNEX C – RECOMMENDED TORQUE VALUES FOR BOLTING
Document DT01e- D - Published on: 01 July 2002 Page C.1

Annex D - Material Working Temperature Limits
ANNEX D – MATERIAL WORKING TEMPERATURE LIMITS
Material designation Min. Working Temperature Max. Working temperature
A105N -29°C Not for prolonged use over 425°C

A350 LF2 -46°C Not for prolonged use over 425°C
A182 F5 -29°C Not for prolonged use over 650°C
A182 F11 Cl. 2 -29°C Not for prolonged use over 595°C
A182 F22 Cl. 3 -29°C Not for prolonged use over 595°C
A350 LF3 -101.1°C Not for prolonged use over 345°C
A182 F304H -29°C Not for prolonged use over 815°C
A182 F304 -196°C Not for prolonged use over 815°C1
A182 F316 -196°C Not for prolonged use over 815°C1
A182 F91 -29°C -
A193 B7 +20°C -
A193 B7M +20°C -
A193 B16 +20°C -
A193/A320 B8 -196°C -
A193/A320 B8 Cl. 2 -196°C -
A193/A320 B8M Cl. 2 -196°C -
A193/A320 B8M -196°C -
A320 L7 -101°C -
1
Use above 540°C only when C content is 0.04 or higher
Document DT01e- D - Published on: 01 July 2002 Page D.1

Annex D - Material Working Temperature Limits
Material designation Min. Working Temperature Max. Working temperature
A320 L7M -73°C -

B564 NO4400 -196°C Up to 482°C
B381 F2 -60°C Not for prolonged use over 315°C
A694 F60 -46°C -
B462 N08020 -196°C -
B564 NO6600 -196°C Up to 648°C
Pagina D.2 Document DT01e- D - Published on: 01 July 2002

Annex E - Material Corrosion Guide
ANNEX E – MATERIAL CORROSION GUIDE
Stainless Steel 316
Stainless Steel 316

Stainless Steel 304
Stainless Steel 304

Carbon Steel
Carbon Steel
CORROSIVE MEDIA CORROSIVE MEDIA
Inconel
Inconel
Monel
Monel
Acetate Solvents, Crude D A A A B Ferric Nitrate, 5% D B A C D
Acetate Solvents, Pure C A A A A Ferric Sulfate, 5% D B A B C
Acetic Acid, 95% D B A A A Ferrous Sulfate, 10% C A A B A
Acetic Anhydride, Boiling D B A A A Flourine, Dry Gas C C B A A
Acetone B A A A A Flourine, Moist Gas D D D B A
Alcohols B A A A A Freon, Wet C C C B A
Amines B A A A A Fuel Oil, 140°F A A A A B
Ammonia, Anhydrous B A A A A Furfural B B B B B
Ammonium Hydroxide, Hot B A A A D Gasoline Sour B A A C C
Ammonium Nitrate B A A A C Gasoline Refined A A A B A
Aniline Hydrochloride D D C B B Gelatine D B A A A
Antimony Trichloride D D C B B Glucose B A A A A
Asphalt B A A A A Glycerine B A A A A
Barium Chloride, 5% C A A A A Hydrofluoric Acid, Boiling D D D D B
Barium Hydroxide C A A A A Hydrofluosilicic Acid D D C B A
Barium Nitrate C A A B C Hydrogen Chloride, Dry B D C A A
Benzene, Hot B A A A A Hydrogen Chloride, Moist D D D D C
Benzoic Acid B A A A A Hydrogen Fluoride, Dry C D C A A
Blood D A A A A Hydrogen Peroxide, Boiling D C B B B
Bromine, Dry Gas D A A B A Hydrogen Sulfide, Dry B A A A A
Bromine, Moist Gas D D D D C Hydrogen Sulfide, Moist C B A A B
Buttermilk D A A A A Iodine, Dry D D B A A
Calcium Bisulfite, Hot D C B D D Kerosene A A A A A
Calcium Chloride, Dilute C B A A A Lactic Acid, 5% D B A A B
Calcium Hydroxide, 20%, Boiling D A A A A Lactic Acid, 10% D B A A B
Calcium Hydrochloride, < 2% C C B B C Lactic Acid, Boiling, 5% D C B B C
Carbolic Acid, 90% C A A A B Lactic Acid, Boiling, 10% D D B B C
Carbon Dioxide, Dry C A A A A Lead Acetate, Hot D A A B B
Carbon Disulphide B A A A B Magnesium Chloride, Hot, 5% D C B A A
Chloroacetic Acid D D C B B Magnesium Hydroxide B A A A A
Chloric Acid D D C C C Magnesium Sulfate B A A B A
Chlorinated Water, Sat. D D C C C Magnesium Sulfate, Boiling C A A C A
Chlorine, Dry Gas B B B A A Mercury B A A A B
Chlorine, Moist Gas D D C D C Mercuric Chloride, < 2% D D D D D
Citric Acid, Dilute D A A A A Mercuric Cyanide D B B B D
Citric Acid, Hot, Conc. D C B B B Methyl Chloride, Dry D B B A A
Creosote, Hot B A A A A Milk D A A A B
Cupric Chloride, 5% D D C D D Molasses B A A A A
Ethyl Chloride A A A A A Naptha B A A A A
Ethylene Glycol A A A A A Nickel Chloride D C B B B
Ferric Chloride < 1% D C B B C Nickel Sulfate, Boiling D C C B A
Document DT01e- D - Published on: 01 July 2002 Page E.1

Annex E - Material Corrosion Guide
Stainless Steel 304
Stainless Steel 304

Stainless Steel 316
Stainless Steel 316

Carbon Steel
Carbon Steel
CORROSIVE MEDIA CORROSIVE MEDIA
Inconel
Inconel
Monel
Monel
Nitric Acid, 20% D A A B D Sodium Perborate C A A A B
Nitric Acid, Boiling, Conc. D D D D D Sodium Peroxide C A A A B
Nitrous Acid D B B B C Sodium Phosphate, Tribasic C A A A A
Nitrobenzene D B A B B Sodium Silicate B A A A B
Oils - Miner. B A A C B Sodium Thiosulfate D B A B B
Oxalic Acid, Boiling, 10% C A A A A Stannous Chloride, Sat. D D B B B
Oxalic Acid, Boiling, 50% D D C B B Steam, 212°F A A A A A
Oxygen B A A A A Steam, 600°F C A A A A
Picric Acid C A A D D Sulfite Liquors D C B D D
Potassium Bromide D C B A A Sulfur Chloride D C D B B
Potassium Carbonate B A A A A Sulfur Dioxide, Moist D B A D D
Potassium Chlorate B A A A B Sulfuric Acid, Conc. B B B B D
Potassium Chloride D A A A A Sulfurous Acid, Sat. D B B D D
Potassium Chloride, Hot D C B B A Tannic Acid, 10% D A A B A
Potassium Cyanide B B B B B Tar, Hot B A A A B
Potassium Sulfate, Dil. B A A A A Tartaric Acid, 120°F D B A A A
Propane, Liquid & Gas B A A A A Toluene A A A A A
Pyrogallic Acid B A A B A Trichlorethylene B A A A A
Rosin, Molten D A A A A Turpentine B A A A A
Salicylic Acid D B B B B Varnish, Hot C A A A A
Silver Bromide D B A C B Vegetable Oils B A A A B
Silver Chloride D D D C B Vinegar D A A A A
Silver Nitrate D A A A C Water, Acid Mine D A A A C
Sodium Acetate C A A A A Water, Boiler Feed B A A A A
Sodium Bisulfate D B B B A Water, Distilled D A A A A
Sodium Bromide, Dil. D B B B A Water, Salt Sea D C B B A
Sodium Cyanide B B B B A Whiskey, Boiling D A A A C
Sodium Fluoride, 5% D B A B A Wine D A A A C
Sodium Hydroxide, 50% B A A A A Xylene, Boiling D A A A A
Sodium Hyposulfite D B A B A Zinc Chloride, 5% D C B B B
Sodium Nitrate B B A A B Zinc Sulfate, Boiling D A A B A
A = Substantial resistance - Preferred material of construction.

B = Moderate resistance - Satisfactory for use under most conditions.
C = Questionable resistance - Use with caution.
D = Inadequate resistance
LVF doesn't assume any responsibility from the use of a.m. data which are purely theoretical.
The user must verify the best conditions of use.
Pagina E.2 Document DT01e- D - Published on: 01 July 2002

ELECT.SIGN D:Cagliani C:Cagliani A1:Cagliani
IQ Range
Installation and
Maintenance Instructions
This manual contains important safety

information. Please ensure it is thoroughly
read and understood before installing,
operating or maintaining the equipment.
Publication number E170E3

Date of issue 10/05
The Rotork Setting Tool allows actuator control, indication and
protection functions to be configured to suit site requirements.
In addition, the new Setting Tool Pro also allows downloading
of datalogger and uploading/downloading of configuration
files. Files are transferred to and from the Setting Tool Pro via
Rotork Insight.
It is essential that all the actuator settings are checked for

compatibility with the valve, process and control system
requirements before the actuator is put into service. Please read
this publication.
Rotork Setting Tool Pro
When Rotork personnel or nominated agents are contracted to
carry out site commissioning and/or acceptance, documentation
of commissioned actuator configuration can be made available
for customer records.
Rotork Setting Tool

This manual provides instruction on: THE ROTORK IQ RANGE – THE FIRST VALVE ACTUATOR THAT YOU
CAN COMMISSION AND INTERROGATE WITHOUT REMOVING
* Manual and electrical (local and remote) operation. ELECTRICAL COVERS.
* Preparation and installation of the actuator onto Using the supplied infra-red Setting Tool to access the actuator set up
procedures, non-intrusive setting of torque levels, position limits and all
the valve.
other control and indication functions can be made safely, quickly and
conveniently, even in hazardous locations. The IQ allows commissioning
* Subsequent commissioning and adjustment of the and adjustment to be carried out with the main power supply to the
Basic Settings for correct valve operation. actuator switched on or off.
* Commissioning and adjustment of the Configuration Standard diagnostics access information about the control system, valve
and actuator status is in the form of display text and help screens.
Settings to suit site-specific control and indication
requirements. Setup, Alarm and Status text is available in English (default), Spanish, French
and German.
* Maintenance – Troubleshooting.
Instantaneous valve torque and position can be monitored on the actuator
* Sales and Service. with a single key press of the Setting Tool.
The on board Datalogger captures operational and valve torque data

enabling informed maintenance choices to be made. IQ Insight software
for PC and PDA allows the Datalogger to be interrogated, as well as the
Refer to Publication E180E2 for repair, overhaul and complete actuator set up to be configured and recorded.
spare part instructions.
The actuator containing the Setting Tool will be identified with a yellow
label on the terminal cover.
Visit our web site at www.rotork.com for more information on the IQ,
IQ Insight and other Rotork actuator ranges.
CONTENTS
Page Page Page

1 Health and Safety 2 5.5 IQM Modulating Actuators 12 9 Commissioning –
2 Storage 3
5.6 IQML Linear Drive Unit 12 Configuration Settings 31
5.7 IQML Adjusting Linear Stroke 13 Configuration Settings Contents 33
3 Operating your IQ Actuator 3 Default Options 63
6 Cable Connections 14
3.1 Operating by Hand 3
3.2 Operating Electrically 3
6.1 Earth/Ground Connections 14 10 Maintenance, Monitoring
3.3 Display – Local Indication 4
6.2 Removing Terminal Cover 14 and Troubleshooting 65
6.3 Cable Entry 14 10.1 Setting Tool Pro Download & Upload 68
3.4 Display Status Indication – Travel 5
6.4 Connecting to Terminals 15 10.2 Help Screens 71
3.5 Display Status Indication – Control 5
6.5 Replacing Terminal Cover 15 10.3 IQ Infrared Diagnostic & Configuration 76
3.6 Display Alarm Indication 5
7 Commissioning 16 10.4 Environmental 77
4 Preparing Drive Bush 7
4.1 IQ10 to IQ35 7
7.1 The Setting Procedure 16 11 Weights and Measures 78
7.2 The Rotork Setting Tools 17 Binary, Hexadecimal and Decimal
Thrust Base Types A and Z
7.3 Entering the Actuator 20 Conversion Table 79
4.2 IQ10 to IQ35 8
Setting Procedure
Non-Thrust Base Type B 12 IQ Approvals 80
7.4 Setting Mode – Password 20
4.3 IQ40 to IQ95 8
Thrust Base Types A and Z 7.5 New Password 20
4.4 IQ40 to IQ95 9 7.6 Checking Mode 20
Non-Thrust Base Type B 7.7 Crossroad 21
7.8 The Actuator Display – 21
5 Mounting the Actuator 10 Setting/Checking Mode
5.1 Rising Stem Valves – Top Mounting 11 7.9 Returning to Valve Position Display 21
5.2 Valve with Gearbox – Side Mounting 12
5.3 Non-Rising Stem Valves – Top Mounting 12 8 Commissioning –
5.4 Handwheel Sealing 12
Basic Settings 22
Basic Settings Contents 23

1 Health and Safety
This manual is produced to enable a given in the applicable edition of the No inspection or repair should be than 150V AC but below 300V AC
competent user to install, operate, “IEE Wiring Regulations’’ should be undertaken unless it conforms to the (refer to actuator wiring diagram),
adjust and inspect Rotork IQ range applied. Also the user should be fully specific hazardous area certification the actuator installation altitude must
valve actuators. Only persons aware of his duties under the Health requirements. Under no circumstances be restricted to less than 2000m as
competent by virtue of their training and Safety Act 1974. should any modification or alteration be defined by BSEN 61010 or IEC 61010
or experience should install, maintain carried out on the actuator as this could (Safety Requirements For Electrical
For the USA: NFPA70, National Electrical
and repair Rotork actuators. Work invalidate the actuators hazardous Equipment for measurement, control
Code ® is applicable.
undertaken must be carried out in area approval certification. Access to and laboratory use).
accordance with the instructions in The mechanical installation should be live electrical conductors is forbidden
this and any other relevant manuals. in the hazardous area unless this is
WARNING: Enclosure Materials
carried out as outlined in this manual
The user and those persons working and also in accordance with relevant done under a special permit to work, IQ10 to IQ35 are manufactured from
on this equipment should be familiar standards such as British Standard otherwise all power should be isolated aluminium alloy with stainless steel
with their responsibilities under any Codes of Practice. If the actuator has and the actuator moved to a non- fasteners and the thrust bases are
statutory provisions relating to the nameplates indicating that it is suitable hazardous area for repair or attention. manufactured in cast iron.
Health and Safety of their workplace. for installation in hazardous areas then IQ40 to IQ95 enclosures are manufactured
Due consideration of additional the actuator may be installed in Zone WARNING: Motor Temperature in aluminium alloy and cast iron with
hazards should be taken when using 1, Zone 21, Zone 2 and Zone 22 (or Div Under normal operation the temperature stainless steel fasteners and the thrust
the IQ range of actuators with other 1 or Div 2, class I or Class II) classified of actuator’s motor cover surfaces can bases are manufactured in cast iron.
equipment. Should further information hazardous area locations only. It should exceed 60°C above ambient.
and guidance relating to the safe use not be installed in hazardous area The user must ensure that the operating
of the Rotork IQ range of actuators be locations with an ignition temperature WARNING: Thermostat Bypass environment and any materials
required, it will be provided on request. less than 135°C, unless suitability for If the actuator is configured to bypass surrounding the actuator cannot lead
lower ignition temperatures has been the motor thermostat then the hazardous to a reduction in the safe use of, or the
The electrical installation, maintenance protection afforded by, the actuator.
indicated on the actuator nameplate. area certification will be invalidated.
and use of these actuators should be
It should only be installed in hazardous Additional electrical hazards may occur Where appropriate the user must
carried out in accordance with the
area locations compatible with the gas when using this configuration. The ensure the actuator is suitably protected
National Legislation and Statutory
groups stated on the nameplate. user should ensure that any necessary against its operating environment.
Provisions relating to the safe use of
additional safety measures are considered.
this equipment, applicable to the site of The electrical installation, maintenance
installation. and the use of the actuator should be WARNING: Control and Indication WARNING: Operating by Hand
carried out in accordance with the code With respect to handwheel operation of
For the UK: Electricity at Work Where the actuator build allows remote
of practice relevant for that particular Rotork electric actuators, see warning
`Regulations 1989 and the guidance control and indication supplies higher
Hazardous Area certification. on p3.

2 Storage 3 Operating your
IQ Actuator
If your actuator cannot be installed 3.1 Operating by Hand To engage handwheel drive depress the When the selector is locked in the Local
immediately store it in a dry place until Hand/Auto lever into “Hand” position or Remote positions the Stop facility is still
you are ready to connect incoming and turn the handwheel to engage the available. The selector can also be locked
cables. WARNING clutch. The lever can now be released in the Stop position to prevent electrical
With respect to handwheel where it will return to its original operation by Local or Remote control.
If the actuator has to be installed but
position. The handwheel will remain
cannot be cabled it is recommended operation of Rotork electric
engaged until the actuator is operated
that the plastic transit cable entry plugs actuators, under no circumstances electrically when it will automatically
are replaced with metal plugs which are should any additional lever disengage and return to motor drive.
sealed with PTFE tape. device such as a wheel-key If required the Hand/Auto lever can
The Rotork double-sealed construction or wrench be applied to the be locked in either position using a
will preserve internal electrical handwheel in order to develop padlock with a 6.5mm hasp.
components perfectly if left more force when closing or
undisturbed. opening the valve as this may 3.2 Operating Electrically
cause damage to the valve and/or Check that power supply voltage agrees
It is not necessary to remove any with that on the actuator nameplate.
electrical compartment covers in order actuator or may cause the valve
to become stuck in the seated/ Switch on power supply. It is not
to commission the IQ actuator. necessary to check phase rotation.
backseated position.
Rotork cannot accept responsibility for Fig. 3.1
deterioration caused on-site once the Do not operate the actuator
covers are removed. electrically without first checking, Local Control
using the infra-red Setting Tool, With the red selector positioned at Local
Every Rotork actuator has been fully (anti-clockwise) the adjacent black knob
tested before leaving the factory to that at least the Basic Settings can be turned to select Open or Close.
give years of trouble free operation, have been made (refer to Section For Stop, turn red knob clockwise.
providing it is correctly commissioned, 8 page 22).
installed and sealed.
Selecting Local/Stop/Remote Remote Control
Operation Rotate the red selector to the Remote
The red selector enables either Local or position (clockwise), this allows remote
Remote control, lockable in each position control signals to operate the actuator.
Fig. 3 using a padlock with a 6.5mm hasp. Local Stop can still be used by turning
the red knob anti-clockwise.

3.3 Display–Local Indication description text in the lower display. Open Closed
The two tri-colour LED's will be Red, The two tri-colour LED's will be Green,
6. Battery Alarm Icon - This icon will be
the open symbol and "Open Limit" will closed symbol and "Closed Limit" will
displayed when a battery is detected as
be displayed be displayed.
low or flat. "Battery low" or "flat" will
also be displayed in the lower display.
7. IR Icon - This icon flashes during infra
red communication activity.
8. Percentage Open Icon - This icon will
be displayed when a percentage Open Open Limit Closed Limit
value is in the upper display.
The liquid crystal display screen has 2 Fig. 3.3 Fig. 3.5
modes of position indication:
Fig. 3.2 The Actuator Display With the main power supply switched
1. Valve position – power on Mid Travel off, the display screen is powered by
The display consists of: 2. Valve position – power off The two tri-colour LED's will be Amber, a battery and continues to display
percentage open value will be shown actuator position. However, the battery
1. Position Display - This is the main On power up the actuator’s liquid and "Stopped" will be displayed when
7-segment position display with icons. does not support screen back-lighting,
crystal display screen is back-lit with an there is no actuator movement. position indicator lamps or dot matrix
2. Text Display - This is a 2 line, 16 amber light and one of the indicator display.
characters dot matrix display which lamps will be on, dependent on
allows text to be used to compliment position. The display screen will show LED Indicators
the position display and icons. percentage open or an end of travel
symbol. (See Figs 3.3, 3.4 and 3.5)
3. Infra Red LED's. WARNING: Mid Travel LED
As standard, red lamp signifies valve colour may be affected by viewing
4. 2x Tri-colour LED's for position open, amber intermediate, and green Stopped angle and lighting level.
indication. lamp signifies valve closed. Open and
The Close LED colour can be changed
5. Alarm Icon - This will be displayed closed colour functions can be reversed
to red if required. The Mid Travel amber
for Valve, Control, and Actuator alarms. on request.
LED can be switched off if required.
Alarm indication is supported by fault Fig. 3.4
Refer to Section 9.16, page 62.

3.4 Display Status Indication • Timer Active Interrupter Timer option • Remote Control Remote control 3.6 Display Alarm Indication
– Travel enabled only. Interrupter Timer has selected – red selector.
The IQ display provides alarm indication
stopped the actuator mid travel for a
The IQ display provides real time status • Local Close Local close signal applied in the form of text and alarm icons.
indication. The top line of the text period equal to the set Timer Off
– black selector.
display is reserved for travel status time. Refer to 9.13 page 59. There are 2 alarm icons:
• Local Open Local open signal applied
indication. Fig 3.6 shows the travel
– black selector.
status example Closed Limit .
3.5 Display Status Indication • Remote Close Remote close (hardwired General Alarm:
– Control or analogue) signal applied.
The bottom line of the text display is
• Remote Open Remote open (hardwired Battery Alarm:
reserved for control status indication
or analogue) signal applied.
and is displayed for approximately 2
seconds after the control mode or • Remote ESD Remote hardwired
Closed Limit signal is applied. Fig 3.7 shows the emergency shut down signal applied.
control status example Remote Control . General Alarm
• Remote Bus Open Remote Bus * open
signal applied. The general alarm icon will be
Fig. 3.6 supported with text in the bottom line
• Remote Bus Close Remote Bus* signal indicating the particular alarm, or if
Available travel status conditions displayed: applied. more than one is present, each alarm
• Closed Limit Actuator has reached the • Remote Bus ESD Remote Bus* will be displayed in sequence.
set closed limit position. Closed Limit emergency shut down signal applied. Fig 3.8 shows the status example
• Open Limit Actuator has reached the Remote Control * Bus Control option fitted may be TORQUE TRIP CL .
set open limit position. Pakscan, Profibus, Modbus,
• Moving Open Actuator is traveling in Fig. 3.7 DeviceNet or Foundation Fieldbus.
the open direction. Refer to actuator wiring diagram.
Available control status conditions displayed:
• Moving Closed Actuator is traveling in • Local Control Local control selected -
the closed direction. red selector. Stopped
• Stopped Actuator has stopped in a • Local Stop Local stop selected – red TORQUE TRIP CL
mid travel position, indicated in the selector.
top display (%open). Fig. 3.8

Available alarm conditions displayed: Actuator Alarms • TORQ SENSOR FAIL Detected failure When a low or flat battery
in the torque sensing system alarm is displayed the battery
Valve Alarms • THERMOSTAT TRIP Motor thermostat
– contact Rotork. should be replaced immediately. It
has tripped due to the motor
• TORQUE TRIP CL tripped off on torque is essential that the correct battery
overheating. Operation is inhibited • EEPROM MISSING Contact Rotork
while moving in the close direction. type is fitted to maintain actuator
until the thermostat resets
• TORQUE TRIP OP tripped off on torque automatically when the motor cools. certification. Refer to page 65.
while moving in the open direction. Check actuator duty cycle against Battery Alarm After replacing a battery the
process requirements (running time, alarm icon will continue to be
• MOTOR STALLED no movement torque, ambient temperature).
detected after a signal to move. displayed until the next check and
• PHASE LOST (3-phase models only). may take up to 1 hour. Cycling the
Control Alarms The phase supply the actuator power will force a battery check
connected to terminal 3 is lost. and clear the alarm.
• ESD ACTIVE ESD signal applied. When
present the ESD signal overrides all
Operation is inhibited.
Open Limit
local and remote control signals. • 24V LOST The 24 volt customer BATTERY LOW PWR LOSS INHIBIT
Once the ESD action is carried out supply (terminals 4 & 5) has tripped.
operation is inhibited while the ESD Check remote control wiring. Supply Fig. 3.7 If, on power up, the actuator detects
signal is maintained. Refer to 9.3 is protected with a resettable fuse. a discharged battery and actuator
ESD Action page 36. The actuator checks the battery level power loss inhibit feature [OS] is
• LOCAL CONTROL FAIL Check operation
at approximately 1 hour intervals. The enabled (refer to page 61), both
• INTERLOCK ACTIVE Open and/or close of control selectors (black and red).
battery alarm icon is displayed when battery and general alarm icons will
interlocks are configured on and are • CONFIG ERROR There may be an error the actuator detects its battery as be displayed and the bottom line will
active. Refer to 9.3 Interlockpage 38. in the configuration (set up) of the being low and the display will indicate indicate alternately PWR LOSS INHIBIT
Operation in the direction of an actuator. Check and reset basic BATTERY LOW . and BATTERY FLAT . Electrical operation
active interlock(s) is inhibited. setting and check configuration will be inhibited. The battery must
Note that when conditional control is settings. If the battery is flat or missing the
be replaced and the limits must be
configured, an active interlock will display will indicate BATTERY FLAT .
• POS SENSOR FAIL Detected failure in reset. Refer to Section 10, page 66 and
not inhibit local control operation. Section 8, page 29.
the position sensing system – contact
Rotork.

4 Preparing Drive Bush
4.1 IQ10 to IQ35 2. Unscrew the bearing stop from the assembly working loose, as shown in
Thrust Base Types A and Z drive bush. Slide the bearing off the Fig 4.2. Refer to the table below for
drive bush. Keep the drive bush and required tightening torques.
Removal of Drive Bush for stop ring in a safe clean place.
Machining Socket set Allen key Torque Torque
3. For all sizes ensure the drive bush screw size bit size Nm lbs/ft
male thread (stop ring) is not
damaged during machining. For sizes M4 M2 2.2 1.62
IQ20, IQ25 & IQ35, ensure the O-ring
M6 M3 7.8 5.75
located in the drive bush is not
damaged during machining. Machine
drive bush to suit the valve stem,
allowing generous clearance on the
Fig. 4.1 Components of Type A screw thread for rising stem valves.
Thrust Base Re-assembly
bearing stop ring. The bearing stop ring 1. Remove all swarf from the drive
is locked with one socket set screw. bush, ensuring the O rings on the
drive bush and bearing stop ring
Fig. 4 Bronze Drive Bush Fitted into (where fitted) are undamaged, clean
IQ20, IQ25 and IQ35 have a thrust race and greased.
Thrust Taking Base
ball bearing within the steel bearing
Turn actuator onto its side, remove the housing, located on the drive bush 2. Slide the bearing assembly onto the Fig. 4.2
two cap-headed screws holding base and retained by the steel bearing stop drive bush and ensure it is fitted
plate onto thrust base, pull out the ring. The bearing is sealed within its down to the drive bush shoulder. 4. Refit the drive bush assembly into
drive bush complete with its bearing housing by O-rings located on the drive the base casting on the actuator,
3. Screw the stop ring with the locking ensuring that the slots in the drive
assembly. bush and on the bearing stop ring. The
socket set screw(s) uppermost on to bush are located into the drive dogs
Before machining the drive bush the bearing stop ring is locked with two
the drive bush until it comes to a of the hollow output shaft.
thrust bearing must be removed. socket set screws.
stop – hand tight and lock with the
IQ10, IQ12 and IQ18 actuators have a locking socket set screws. The 5. Refit the base plate and secure with
sealed thrust bearing located on the 1. Locate and loosen the locking socket locking socket set screws must be cap-headed screws.
drive bush and retained by the steel set screw(s) in the bearing stop ring. done up tight to prevent the

4.2 IQ10 to IQ35

Non-Thrust Base Type B
Undo the four set screws securing the
base plate to the gearcase and remove
the base plate.
The drive bush and its retaining clip can
now be seen.
Types B3 and B4 removal:
(refer to Fig. 4.3)
Fig. 4.4 Fig. 4.7 Type A Drive Bush
Using external circlip pliers, expand the Fig. 4.5 Locating Set Screw
circlip while pulling on the drive bush. Type B1 If the actuator has a type A drive bush
The drive bush will detach from the (Refer to Fig. 4.4) Loosen set screw and unscrew retainer (Fig. 4.7) this can be fitted in position
The procedure for removal and refitting using hammer and punch. Remove 1 or 2 to suit the position of the valve
actuator centre column with the circlip
of the B1 drive bush is the and same drive bush and machine to suit valve mounting flange.
retained in its groove. as for B3 and B4, However the circlip is stem or gearbox input shaft.
replaced with a custom spring clip. The
spring clip operates in the same manner Allow generous clearance on screw
as the B3/B4 circlip but is expanded thread for rising stem valves.
using long-nose pliers.
4.3 IQ40 to IQ95

Removal of Drive Bush for
Machining
Engage “hand” and turn handwheel
until retainer set screw is visible through
hole in actuator base. Fig. 4.8 Type A Drive Bush in
Position 1
Fig. 4.3
Fig. 4.6 Removal of Retainer

Fig. 4.9 Type A Drive Bush in Fig. 4.11 Type Z3 Drive Bush in
Position 2 Position 3
Fig. 4.13 B3/B4 Drive Bush
If the actuator has a type Z3 drive bush Re-Assembly
(Fig. 4.10) this can only be fitted below Having confirmed the position required,
the actuator base (Fig. 4.11). insert the machined drive bush ensuring
that the actuator output shaft dogs
are in full engagement with the bush. Fig. 4.12 Tightening Retainer Set
Fit drive bush retainer securely, turning Screw
clockwise until fully tightened using
hammer and punch. Rotate by hand Types B3 and B4
wheel to align retainer set screw with Identical drive bushes secured by cap
hole in the side of base and tighten to headed screws.
18.6 Nm / 13.7 lbsft. B3 is supplied pre-machined to ISO
5210 standard.
4.4 IQ40 to IQ95
Non-Thrust Base Type B B4 is supplied blank and must be
machined to suit the input shaft of the
Type B1 gearbox or valve that it will drive.
Fig. 4.10 Type Z3 Drive Bush Output shaft bored and keyed to ISO
5210 standard. There is no drive bush Fig. 4.14 B3/B4 Drive Bush in Situ
to machine.
10
5 Mounting the Actuator
Refer to Weights and Measures page 78 for actuator weight.

Ensure the valve is secure before fitting the actuator as the combination may be top
heavy and therefore unstable.
If it is necessary to lift the actuator using mechanical lifting equipment certified
slings should be attached as indicated in Fig.5 for vertical valve shafts and Fig.5.1
for horizontal shafts.
At all times trained and experienced personnel should ensure safe lifting,
particularly when mounting actuators.
WARNING:
The actuator should be fully supported until full valve shaft
engagement is achieved and the actuator is secured to the valve
flange.
A suitable mounting flange conforming to ISO 5210 or USA Standard MSS SP101
must be fitted to the valve.
Fig. 5
Actuator to valve fixing must conform to Material Specification ISO Class 8.8, yield
strength 628 N/sq mm.
WARNING:
Do not lift the actuator and valve combination via the actuator. Always
lift the valve/actuator assembly via the valve.
Each assembly must be assessed on an individual basis for safe lifting.
Fig. 5.1
11
5.1 Rising Stem Valves – Fit the machined drive bush into the Torque
Top Mounting thrust base as previously described,
lower the actuator onto the threaded Imperial Size Nm lbs/ft
a) Fitting the Actuator and valve stem, engage “hand” and wind
Base‑as a Combined Unit – 1/4 Hex 12.1 9
the handwheel in the opening direction
All Actuator Sizes to engage the drive bush onto the 5/16 Hex 24.3 17.9
stem. Continue winding until the 3/8 Hex 42.3 31.2
actuator is firmly down on the valve 7/16 Hex 67 49.4
flange. Wind two further turns, fit
securing bolts and tighten fully. 1/2 Hex 103.2 76.1
9/16 Hex 147.4 108.7
b) Fitting Thrust Base to Valve –
Actuator Sizes 10 to 35 only 5/8 Hex 205.3 151.4
Fit the machined drive bush into the Fig. 5.3 3/4 Hex 363.6 268.1
thrust base as previously described. Continue to turn actuator until fixing
Remove the thrust base from the 7/8 Hex 585 431.5
holes align. Using bolts supplied fix
actuator, place it on the threaded actuator to thrust base and tighten down 1 Hex 877.3 647.1
valve stem with the slotted end of the to the required torque, see table A. Torque
drive bush uppermost and turn it in Open valve by two turns and firmly
Fig. 5.2 the opening direction to engage the tighten down fixings onto valve flange Metric Size Nm lbs/ft
thread. Continue turning until the base to the required torque, see table B. M5-Hex 6.2 4.6
is positioned onto the valve flange. Fit
securing bolts but do not tighten at M6-Hex 10.8 7.9
this stage. Lower the actuator onto the M8-Hex 26.1 19.3
thrust base and rotate the complete
actuator until the drive dogs on the M10-Hex 51.6 38
actuator output shaft engage into the Torque M12-Hex 89.2 65.8
drive bush. Actuator flange should now Size Nm lbs/ft M16-Hex 219.8 162.1
be flush with base flange.
M8 Hex Head 14.8 10.9 M20-Hex 430.5 317.5
M12 Hex Head 50.2 37.1 M24-Hex 736.8 543.4
Table A Table B
12
5.2 Valve with Gearbox – 5.5 IQM Modulating Actuators 5.6 IQML Linear Drive Unit
Side Mounting The IQM range of actuators are suitable Consists of a lead screw assembly
Check that the mounting flange is at for modulating control duty of up to arrangement attached to the base
right angles to the input shaft, and 1200 starts per hour in accordance with of the actuator in order to provide a
that the drive bush fits the shaft and IEC 34-1 to S4 50%. linear output stroke between 8mm
key with adequate axial engagement. (3/8 in) minimum and 120mm (43/4 in)
Engage “hand”, offer up actuator to IQM actuators have a dynamic braking
maximum.
the input shaft and turn handwheel facility as standard. If mechanical
to align keyway and key. Tighten overrun of the actuator and valve prove The IQML can be supplied with or
mounting bolts. to be excessive for accurate control, the without a yoke mounting adaptor.
brake can be enabled by fitting a link to This adaptor consists of four pillars and
5.3 Non-Rising Stem Valves – the actuator terminal block as indicated a base flange to suit the valve.
Top Mounting by the wiring diagram. With dynamic
Treat as for side mounting except that braking enabled, motor heating effects
when thrust is taken in the actuator, increase and therefore the number
a thrust nut must be fitted above the of actuator starts should be reduced
drive bush and securely tightened. to prevent motor thermostat tripping
(refer to publication E410E for more
5.4 Handwheel Sealing information).
Ensure that sealing plug in centre of Commissioning of IQM range actuators
handwheel (or spindle cover tube is identical to the standard IQ (refer to Fig. 5.5 IQML without Yoke
depending on which is fitted) is sealed Sections 7, 8 and 9 commencing on
with PTFE tape and fully tightened, page 16).
ensuring that moisture does not
pass down the centre column of the
actuator.
Fig. 5.4 IQML with Yoke

13
5.7 IQML Adjusting Linear Stroke Turn the tubular down stop clockwise
With actuator securely fitted to valve, into the actuator until it comes to a
but with the linear drive disconnected, mechanical stop. If the valve must close
ensure valve is at its fully closed (down) onto its seat by “TORQUE ACTION”
position. then back off (anti-clockwise) the
down stop by one third of one turn
Remove cover tube from actuator (equivalent to 1mm). Run the lock nut
handwheel, locate the down stop down ontothe tubular down stop and
adjustment on the linear drive unit and tighten with two spanners. There is no
with two spanners loosen the lock nut, “up stop” (open) on the linear drive
run the lock nut and tubular down stop unit, the mechanical stop in the valve
to the end of the thread. will give this position. Refit the top
cover tube to the handwheel using PTFE
tape to seal the thread.
The linear drive unit is pre-packed with
grease type Rocol MTS 1000, use this or
an equivalent high temperature-bearing
grease.
A grease nipple is situated in the base
of the actuator to enable lubrication of
the lead screw. Periodically, depending
on usage and temperature, apply two
pumps of a grease gun.
Fig. 5.6 Down Stop two Spanners

Turn the actuator handwheel clockwise,
linear drive will move down towards
the valve spindle, couple linear drive to
valve spindle.
14
6 Cable Connections
6.1 Earth/Ground Connections Actuators containing a Setting Tool or

WARNING: A lug with a 6mm diameter hole is Setting Tool Pro fitted to the inside of
Ensure all power supplies cast adjacent to the conduit entries for the terminal compartment cover are
are isolated before removing attachment of an external protective identified with a self-adhesive yellow
actuator covers. earthing strap by a nut and bolt. An label on the outside of the terminal
internal earth terminal is also provided, compartment cover.
Check that the supply voltage agrees however it must not be used alone as
The wiring code card fixed in the cover
with that stamped on actuator the protective Earth Connection.
is particular to each actuator and must
nameplate. not be interchanged with any other
6.2 Removing Terminal Cover
A switch or circuit breaker must be actuator. If in doubt check the serial Fig. 6.2 - Actuator containing Rotork
Using a 6mm Allen key loosen the four
included in the wiring installation of number on the code card with that of Setting Tool Pro.
captive screws evenly. Do not attempt
the actuator. The switch or circuit the actuator.
to lever off the cover with a screwdriver
breaker shall be mounted as close as this will damage the “O” ring seal A plastic bag in the terminal
to the actuator as possible and shall and may damage the flamepath on a compartment contains:
be marked to indicate that it is the certified unit. • Terminal screws and washers.
disconnecting device for that particular • Spare cover “O” ring seal.
actuator. The actuator must be • Wiring diagram.
protected with overcurrent protection • Instruction book.
devices rated in accordance with
Rotork publication No. E130E Electric
motor performance data for IQ range
actuators.
WARNING:
Actuators for use on phase to Fig. 6.3
phase voltages greater than 600V
a.c. must not be used on supply 6.3 Cable Entry
systems such as floating, or earth- Fig. 6 Only appropriate certified Explosion-
phase systems, where phase to Fig. 6.1 - Actuator containing Rotork Proof entry reducers, glands or conduit
Setting Tool. may be used in hazardous locations.
earth voltages in excess of 600V
a.c. could exist.
15
Remove red plastic transit plugs. Make 6.5 Replacing Terminal Cover
cable entries appropriate to the cable Heading
type and size. Ensure that threaded Ensure cover “O” ring seal and spigot
adaptors, cable glands or conduit joint are in good condition and lightly
are tight and fully waterproof. Seal greased before re-fitting cover.
unused cable entries with a steel or
brass threaded plug. In hazardous areas ATTENTION: RED PLASTIC PLUGS IN CONDUIT ENTRIES ARE FOR TRANSIT ONLY.
an appropriately certified threaded FOR LONG TERM PROTECTION FIT SUITABLE METAL PLUGS.
blanking plug must be used.
ATTENZIONE: I TAPPI IN PLASTICA ROSSA PER L'ENTRATA CAVI SONO SOLO
TEMPORANEI. PER UNA PROTEZIONE PERMANENTE PREGO SOSTITUIRLI CON
6.4 Connecting to Terminals
APPOSITI TAPPI METALLICI.
On EExde enclosure units ATENCION: LOS TAPONES ROJOS DE PLASTICO EN LAS ENTRADAS DE CABLE
connections to the power and SON UNICAMENTE PARA TRANSPORTE. PARA PROTECCION PERMANENTE
control terminals must be made COLOCAR TAPONES METALICOS APROPIADOS.
using AMP type 160292 ring tabs
for power and earth terminals and ACHTUNG: DIE ROTEN PLASTIKSTOPFEN SIND NUR FÜR DEN TRANSPORT
AMP type 34148 ring tabs for the GEEIGNET. FÜR DAVERHAFTEN SCHUTZ SIND DIESE GEGEN GEEIGNETE
control terminals. BLINDSTOPFEN AUSZÜTAUSCHEN.
Refer to the wiring diagram inside the ATTENTION: LES BOUCHONS PLASTIQUES ASSURENT UNE PROTECTION
terminal cover to identify functions of TEMPORAIRE. POUR UNE PROTECTION DEFINITIVE UTILISER DES BOUCHONS
METALLIQUES.
terminals. Check that supply voltage
is the same as that marked on the
actuator nameplate.
Remove power terminal screen.
Begin by connecting these cables and
replace screen.
When all connections are made ensure
wiring diagram is replaced in the
terminal compartment.
16
7 Commissioning
7.1 The Setting Procedure 2. Configuration Settings Actuator Display

The Rotork IQ range of actuators is the Settings covering the control,
first that enables commissioning to be indication and optional 50
Position Display This may be an open or closed symbol
carried out without removing covers. equipment functions.
or a percentage open value.
Setting torque, limit and other functions m
is achieved by using the Infra-Red All IQ actuator functions are 50
Setting Tool. The Setting Tool is certified configured before dispatch to Torque and Position Torque
Refer to Section 10.
Intrinsically Safe to allow commissioning
in hazardous areas.
Rotork standard default settings
unless alternatives have been
m
All the commissioning functions are specified with the order. Should
Password P? k PC k Ir k tP
stored in non-volatile memory in the difficulty be encountered during m
actuator. The Setting Tool enables the
user to view all the functions in turn
commissioning the default Crossroad cr k
settings can be reinstated,
via the actuator display window. As
returning the actuator
m
each function is viewed its setting can
be checked and, if required, changed configuration to its original
within the bounds of that function. manufactured state. Site
Commissioning may be carried out with commissioning can then begin Basic Settings Configuration Settings
main power switched on or off. Refer again (refer to Section 9.18 page 63). Direction Indication Contacts
to page 22 for Power Off Setting.
Limit Actions Control Mode
The setting procedure is divided into The default function should be used Torque Values Options
two stages: with caution as settings selected after
manufacture may be essential for the Limit Positions Help Screens
1. Basic Settings safe operation of the valve and/or plant. Defaults
Settings for end of travel limit
actions, torque values, limit
positions etc.
Note: The Basic Settings must be commissioned first.
17
7.2 The Setting Tool (old version) 8 2

Specification 4
Enclosure IP67
6
Certification EEx ia IIC T4 (intrinsically safe)
FM, INT SAFE, Class I & II Div 1 Groups A B C D E F G, T4A
CSA, Exia, Class I, II Div 1 Groups A B C D
Power supply 9V Battery (supplied and fitted)
Operating range 0.75m (from actuator display window)
1
3
Name Instruction 5
7
1. m Key* Display next function down
2. k Key* Display next function across
3. - Key Decrease/change displayed function’s value or option setting Fig. 7.1 The Setting Tool
4. + Key Increase/change displayed function’s value or option setting Setting Tool Battery Replacement
5. Key Enter displayed value or option setting Battery status can be checked by looking at the Infra-red transmitter window while
depressing any Setting Tool button. A flashing red indicator should be seen.
* Pressing the two arrow keys together returns the actuator display to the position Battery replacement must be carried out in a safe area. To replace
indication mode the battery remove the six caphead screws in the back of the Setting Tool.
Remove the back cover to expose the battery.
Infra-red local operation (when enabled)
In order to maintain hazardous area certification fit only Duracell
5. Key Stop actuator
MN1604 or Rayovac Alkaline Maximum NoAL-9V battery types. Refit cover
6. Key Open actuator ensuring red indicator LED faces the transmitter window in the back cover.
7. Key Close actuator When a button is depressed the Setting Tool transmits the relevant instruction
to the actuator by infra-red pulses and must therefore be directly in front of the
8. Infra-red Transmitter Window actuator indicator window and at a distance no greater than 0.75m.
18
7 Commissioning continued
7.2 The Setting Tool Pro (new version) 2

3
Specification 12
Enclosure IP54 6
Manufacture This Setting Tool Pro has been constructed in accordance with: 7
EEx ia IIC T4 (intrinsically safe) 10
FM, INT SAFE, Class I & II Div 1 Groups A B C D E F G, T4 8
CSA, Exia, Class I Div 1 Groups A B C D
Power supply 2x 1.5V Batteries (supplied and fitted)
4
5
1
Name Instruction 11
Fig. 7.2 The Setting Tool Pro
2. i Key Display previous function up
4. o Key Display previous function across Infra-red local operation (when enabled)
5. - Key Decrease/change displayed function’s value or option setting 9. Key Stop actuator
6. + Key Increase/change displayed function’s value or option setting 10. Key Open actuator
7. m Key Initiate download/upload mode 11. Key Close actuator
8. Key Enter displayed value or option setting 12. Infra-red Transmitter Window
* Pressing these two arrow keys together returns the actuator display to the
position indication mode
19
Download / Upload Function Setting Tool Pro Battery Display Set-Up Mode The examples of displayed functions
This new feature has been introduced Replacement The Setting Tool and Setting Tool Pro Close Action , [C2] and Open Torque , [tO]
with the new Rotork Setting Tool arrow keys are used to access and are shown above. Note that a setting
Battery status can be checked by
Pro. It allows the user to download navigate through the actuator set-up option or value is highlighted.
looking at the Infra-red transmitter
datalogger files and download/upload window while depressing any Setting procedure using the actuator display. This instruction manual uses both code
configuration files. The new tool is Tool Pro button except the download Each actuator function with it's current and text for description.
weatherproof and intrinsically safe button. A flashing red indicator should setting is represented on screen by
and so it can be used safely in all be seen. a combination of code and text. The
environments. For more information Setting Tool change keys (+ and –)
refer to Section 10.1, page 68. Battery replacement must be allow the user to view the available
carried out in a safe area. To replace setting options.
the battery remove the six cap head
screws in the back of the Setting
Function Setting
Tool Pro. Remove the back cover to
Code Code
expose the battery.
In order to maintain hazardous
area certification fit only Duracell
MN1500 or GP Batteries GP15A Close Action
battery types. Refit cover ensuring
red indicator LED faces the Function Close on Torque Setting
transmitter window in the back cover. Option
When a button is depressed the

Setting Tool Pro transmits the relevant Function Setting
instruction to the actuator by infra-red Code Value
pulses and must therefore be directly in
front of the actuator indicator window
and at a distance no greater than
0.75m.
Open Torque
Function 40% Setting
Value
20
7.3 Entering the Actuator 7.4 Setting Mode – Password 7.5 New Password [PC] 7.6 Checking Mode
Setting Procedure To enable setting and adjustment of the To configure a new password, the The actuator function settings can be
With the actuator securely mounted actuator functions the correct password actuator must be in setting mode with checked without entering the correct
on the valve, the mains supply on and must be entered. The factory set (default) the password display – setting mode password. The settings can only be
Local control or Stop selected. password is [ld]. If the actuator has enabled – showing, viewed and not altered. The setting bars
previously been set with a site password will not be seen.
PRESS THE m KEY. this must be entered.
PRESS THE k KEY.
The actuator upper display will remain The display will change to [PC]. Using the
Use the + or - keys to scroll through the + or - key scroll through the available
the same and the lower display will available passwords 00–FF (hexadecimal).
change to Torque value. This will be passwords until the desired password is
With the correct password displayed press
represented by Torque = XX% and a displayed. Enter Password
the enter key.
bar graph. (For instantaneous torque PRESS THE KEY. ID Hex
& position monitoring, refer to Section PRESS THE KEY.
10, page 66.) Two “setting” bars will appear and will Password Display, Checking Mode
remain visible on every function display
Once the procedure has been completed
screen. In addition, "Password Correct"
PRESS THE m KEY. in the required mode
will be displayed for 3 seconds.
Change Password
The actuator display will change and IE Hex
PRESS THE m KEY.
the password protection display will The procedure branch [Cr] (crossroad)
be seen. Password Changed to [IE] display can now be seen (refer to Section
7.7 page 21).
NOTE: The new password becomes
Enter Password
effective the next time setting mode is
Password Correct
entered.
Enter Password Default Password,
ID Hex Setting Mode Enabled
The Actuator Function Settings

can be protected by the Use
of a Password
21
7.7 Crossroad [Cr] 7.8 The Actuator Display – In setting mode the Setting Tool + or 7.9 Returning to
Setting/Checking Mode - keys will cause the setting to be Valve Position Display
Actuator functions as laid out in the changed. In checking mode the settings There are five ways of returning to valve
Basic and Configuration commissioning cannot be altered. position display:
stages, can be individually displayed by
In setting mode, once displayed, a new 1. Approximately 5 minutes after the
Basic Setup using the Setting Tool arrow keys.
setting can be entered into the actuator last Setting Tool operation the
Config Setup The m arrow key will always display memory by pressing the key. display will automatically return to
the FIRST function on the next level The setting will flash off and back on, position display.
To access the Basic Settings press DOWN within the procedure. confirming its selection, and "Stored "
the arrow m key (refer to Section 8 will be displayed for 2 seconds in the 2. Press the m and k arrow keys
Commissioning Basic Settings page 22). The k arrow key will always display text display. together.
the NEXT function on the SAME level
To access the Configuration Settings and will wrap around the functions on 3. Press the m arrow key until the
press the arrow k key (refer to TOP LEFT display returns to position.
the same level. PORTION
Section 9 Commissioning Configuration 4. Select Remote control using the
The actuator display indicator lamps will Function e.g.
Settings page 31). red Local/Stop/Remote selector.
continue to indicate valve position but tC = Torque Close
will also flash during IR communication. 5. If you have the new Setting Tool
TOP RIGHT Pro then you can use the iarrow
Actuator functions are displayed in PORTION
code form in the top left portion of the key to return to position display.
Function Setting
liquid crystal display screen. Close Torque
e.g. Value = 40%
40%
The setting for the displayed function is
shown in the top right hand portion of LOWER DISPLAY
the screen. Depending on the actuator Function: Close Torque
function displayed, its setting may be Setting Value: 40%
an option or a value.
Text relating to the function and setting Typical Actuator Function Display
values will be displayed in the lower Setting Mode Enabled
display.
22
8 Commissioning –
Basic Functions
ELECTRICAL OPERATION MUST Power Off Setting
NOT TAKE PLACE UNTIL THE BASIC IQ allows settings to be viewed and
SETTINGS HAVE BEEN MADE AND set without main power. To enable this
CHECKED. function, engage handwheel drive and
rotate until the output drive moves
The actuator’s Basic Settings affect
(refer to page 3). The Setting Tool can
the correct operation of the valve by
now be used. As long as a Setting
the actuator. If the actuator has been
Tool key press takes place within the
supplied with the valve, the valve maker
30 seconds timeout period, Power
or supplier may have already made
Off Setting will remain enabled. If no
these settings.
infra-red Setting Tool communication
This instruction assumes setting mode takes place the display will return to
has been entered (refer to section 7.4 indicating position. The actuator must
page 20). then be operated by handwheel to
re-enable Power Off Setting.
Viewing the Basic Settings
With the actuator mounted on the Settings and operation must
valve, the power supply on and Local be verified by electric operation
or Stop control selected, point the
Setting Tool at the actuator indicator and function test of the actuator
window from a distance of no more to ensure correct operation.
than 0.75m. By pressing the m key
and, when appropriate, the k key,
it is possible to move through the
procedure, displaying the various
functions and their settings as shown
in Fig. 8.1 (refer to page 23).The
right-hand side of Fig.8.1 explains the
function of each LCD display.
Fig. 8
23
Function Description

50 Position Display REFER TO SECTION 7, COMMISSIONING
(This may be an open or closed symbol or a % open value.)
m m
50 Torque and Position Display
Torque
m m
P? k PC k Ir k tP Password k Password Change k IrDA k Torque Reference Profile
m m
Cr k Configuration Crossroad k Configuration Settings, refer to page 32.
C1 k C2 k C3 Direction to Close k Close Action k Open Action BASIC SETTINGS CONTENTS

m m page
tC k tO Torque Value Closing k Torque Value Opening C1 Direction to Close 22
C2 Close Action 23
m m
C3 Open Action 24
LC k LO Limit Closed k Limit Open tC Torque Value Closing 25
m m tO Torque Value Opening 26
50 Position Display LC Set Limit Closed 27
LO Set Limit Open 27
Fig. 8.1 Basic Setting Displays
24
C1 Direction to Close
The actuator can be configured to be Using the + or - key, display the Having ensured that the display
clockwise or anti-clockwise to close. character conforming to correct closing corresponds to the established
Manually operate actuator and valve direction. closing direction
to establish correct closing direction.
Conversion Handwheel direction labels
PRESS THE KEY.
are available. The displayed option will flash (stored),
indicating that it has been set.
50 PRESS THE k KEY.
Close Direction
m Clockwise
50 [C] in the Setting Field Indicating
Torque
Clockwise to Close
m
P? k PC k Ir k tP
m
cr
m Close Direction
Anticlockwise
c1 k c2 k c3
[A] in the Setting Field Indicating
m Anti-clockwise to Close
tC k tO
m
LC k LO
m
50
25
C2 Close Action
The actuator can be configured to close Using the + or - key, display the NOTE: When set to close on torque,
on torque for seating valves and limit Refer to valve manufacturer
required option. the actuator will apply the level of
for non-seating valves. for recommended setting.
torque as set for [tC] in seating the
In the absence of valvemaker valve (refer to [tC] page 27).
instructions refer to the following table
50 Valve type Close Open Close Action

m Close on Limit
Wedge gate “torque” “limit”
50 Globe “torque” “limit” [CL] in the Setting Field Indicating
Torque
Butterfly “limit” “limit” Close on Limit - default setting.

m Thru conduit “limit” “limit”
P? k PC k Ir k tP Ball “limit” “limit”
Plug “limit” “limit”
m Sluice gate “limit” “limit”
cr Penstock “limit” “limit”
Close Action
Parallel slide “limit” “limit”
m Close on Torque
c1 k c2 k c3 [Ct] in the Setting Field Indicating
m Close on Torque.
tC k tO
m
LC k LO Having selected the required option
m PRESS THE KEY.
50 The displayed option will flash (stored),
PRESS THE k KEY.
26
C3 Open Action
The actuator can be configured to Using the + or - key display the NOTE: When set to open on torque,
open on torque for back seating valves required option. the actuator will apply the level of
or limit for non back seating valves. torque as set for [tO] in back seating
the valve (refer to [tO] page 28).
Refer to valve manufacturer
for recommended setting. In the
absence of valvemaker instructions
set “Open Limit”. Open Action
Open on Limit
50 [OL] in the Setting Field Indicates
Open on Limit - defualt setting.
m
50
Torque
m
P? k PC k Ir k tP
Open Action
m Open on Torque
cr [Ot] in the Setting Field Indicates
m Open on Torque.
c1 k c2 k c3
m PRESS THE KEY.
tC k tO The displayed option will flash (stored),
m
PRESS THE k KEY.
LC k LO
m
50
27
tC Close Torque
The value of torque available in the Using the + and - keys, the display
close direction can be configured. recommended value. In the absence of
a recommended torque value, try a low
setting and increase until satisfactory
for recommended value. Close Torque
valve operation is achieved.
40%
The closing torque value can be varied
between 40% and Rated (100%), in If the actuator fails to 40% of Rated Torque
1% increments. complete a closed valve operation
due to the set torque being
reached (Torque Trip CL Alarm, page 5)
50 this may indicate a valve and/or
m process problem or change. It is the
responsibility of the user to ensure Close Torque
50 99%
Torque
the valve and process conditions are
m within specified operational limits
before increasing the Set Close 99% of Rated Torque
P? k PC k Ir k tP torque value.
m PRESS THE KEY.
cr The displayed value will flash (stored),
Close Torque
m indicating that it has been set.
100%
c1 k c2 k c3 Should the set level of torque be
developed in closing, the actuator will Rated Torque
m torque trip and stop.
tC k tO PRESS THE k KEY.
m NOTE: Rated torque is quoted on the
LC k LO actuator nameplate.
m
50
28
tO Open Torque
The value of torque available in the The opening torque value can be NOTE: Rated torque is quoted on the
open direction can be configured. varied between 40% and Rated, in 1% actuator nameplate. Boost torque is at
increments. In addition “Boost” can least 140% of Rated torque.
be configured when no open torque
for recommended value.
protection is required. PRESS THE KEY. Open Torque
100%
The displayed value will flash (stored),
BOOST SHOULD NOT BE indicating that it has been set. Rated
50 SELECTED WHEN THE ACTUATOR
HAS BEEN CONFIGURED TO OPEN
m ON TORQUE (refer to [C3] page 26)
50 UNLESS BACK SEATING AT RATED Should the set level of torque be
developed in opening, the actuator will Open Torque
Torque
TORQUE IS ACCEPTABLE.
m torque trip and stop. Boost
Using the + and - keys, display the
P? k PC k Ir k tP
recommended torque value.
PRESS THE m KEY. Boost
m
In the absence of a recommended
cr torque value, try a low setting and In checking mode, on pressing the m
m increase until satisfactory valve key after reviewing open torque setting,
operation is achieved. Open Torque the display will revert to valve position.
c1 k c2 k c3
40%
m If the actuator fails to
complete a open valve operation 40%
tC k tO
m reached (Torque Trip OP Alarm, page
5) this may indicate a valve and/or
LC k LO
process problem or change. It is the
m responsibility of the user to ensure
the valve and process conditions are Open Torque
50
within specified operational limits 99%
before increasing the Set Open 99%
torque value.
29
LC Set Limit Closed LO Set Limit Open
NOTE: It is possible to set the Open With [LC] displayed 50 With [LO] displayed
Limit Position [LO] first.
m
50
50 Torque
m Set Close Limit

m Set Open Limit
Move to Close P? k PC k Ir k tP Move to Open
50
m
Torque
m Limit Closed Limit Open

Move valve manually to the closed
cr Move valve manually to the open
P? k PC k Ir k tP
m
position. Allow for overrun by m position. Allow for overrun by
winding actuator output open by winding actuator output closed by
cr 1/2 to 1 turn.
c1 k c2 k c3 1/2 to 1 turn.
m PRESS THE KEY.

m
PRESS THE KEY.
c1 k c2 k c3
tC k tO
The two bars will flash (stored) and the The two bars will flash (stored) and the
m closed indicator lamp will illuminate, m open indicator lamp will illuminate,
indicating closed limit position has been LC k LO indicating open limit position has been
tC k tO set. set.
m m
PRESS THE k KEY. 50 PRESS THE m KEY.
LC k LO To check closed limit position hand The open symbol (refer to Fig. 3.3.
m wind valve open until the amber lamp page 4) should now appear.
illuminates. Wind valve back closed NOTE: When in checking mode Set
50 until the closed lamp illuminates. Limit Open [LO] does not appear.
NOTE: When in checking mode Set

Limit Closed [LC] does not appear.
30
Return to
Positional Display
50 If the procedure has been followed as
described, the positional display will
m indicate that the actuator is in the open
50 position.
Torque
m Select Remote control momentarily,

using the red selector to exit setting
P? k PC k Ir k tP procedure and then select required
control: Local, Stop or Remote.
m
With the correct settings made electric
cr
operation can now be carried out
m safely.
c1 k c2 k c3
m
tC k tO
m
LC k LO
m
50
31
9 Commissioning –
Configuration Settings
The Configuration Settings can be Power Off Setting
configured to suit site control and IQ allows settings to be viewed and
indication requirements. It is important set without mains power. To enable
that Basic Settings such as limits and this function, engage handwheel drive
torque switch settings are set before and rotate until the output drive moves
work commences on commissioning by one turn (refer to page 3).The
the Configuration Settings (refer to Setting‑Tool can now be used. As
page 22). long as a Setting Tool key press takes
place within the 30 seconds timeout
The layout of the Configuration
period, Power Off Setting will remain
Settings accessed with the Setting Tool
enabled. If no infra-red Setting Tool
are detailed in Fig. 9.1. To successfully
communication takes place the display
commission the Configuration Settings,
will return to indicating position. The
information about the site or process
actuator must then be operated by
control system will be required.
handwheel to re-enable Power Off
The supplied actuator Wiring Diagram Setting.
details control and indication devices
fitted to the actuator along with Settings and operation must
terminal connection detail and standard be verified by electric operation
remote control wiring systems.
and function test of the actuator
to ensure correct operation.
Fig. 9
32
50 Positional Display
m
Torque
IrDA Torque Reference

m comms Profile
P? k PC k Ir k tP
m Contact Function Value Contact Form
cr k Contact S1 r1 k r1 k r1

m m
Contact S2 r2 k r2 k r2
Primary
m
Functions
m
m ESD ESD Thermostat ESD Overide ESD Override Maintained 2-wire External Conditional Torque Switch
ESD Action Contact Type Bypass Interlocks Local Stop Local Control Control Interlocks Control Bypass
Control Mode A1 k A2 k A3 k A4 k A5 k A6 k A7 k A8 k A9 k At
Configuration
m
Extra Indication 4-20mA Remote Interrupter Setting Tool Power Loss Choose Mid-Travel
Contacts CPT Control Source Timer Local Control Inhibit LED Colour LED Language
Option Selection OE k OI k Od k OJ k Or k OS k OH k OU k UL
m
Option Functions – If Analogue, Bus System or Interrupter Timer control options are fitted their appropriate set-up screens will be automatically inserted here.
m
Software Option 1 Option 2 Service
Version Version Version Reset Password
Service Mode Un k UI k U2 k Ur k UP
m
Help Screens H1 k H2 k H3 k H4 k H5 k H6 k H7 k H8 k H9
m
Default Option d1 k d2
m
Return to Positional Display Fig. 9.1 Configuration Settings
33
9.1 Accessing the
CONFIGURATION SETTINGS Having established that the Basic In order to display the Configuration
Settings have been correctly set, the Settings it is necessary to press the m
page Configuration Settings can now be key until [Cr] appears.
configured to suit site control and
9.1 Accessing the Configuration Settings 33 If you have chosen to enter
indication requirements.
Configuration Settings in the checking
9.2 Indication Contacts S1, S2, S3 and S4 34 It is possible to move through the mode the display will be as Fig. 9.2.
9.3 Control Mode Configuration 36 various Configuration Settings as shown
If you have chosen to enter
9.4 Option Extra Indication Contacts S5–S8 39 in Fig. 9.1 using the k and m keys.
Configuration Settings in the setting
9.5 Option CPT (4-20mA Indication) 40 The actuator wiring diagram will mode the display will be as Fig. 9.3
indicate any options fitted. (refer to Section 7).
9.6 Option Folomatic (Analogue Position Control) 41
9.7 Remote Control Source 44 Options Setting Tool Local Control
[Or] and Power Loss Inhibit [OS] are
9.8 Bus System Option Pakscan 45 standard features, their use being
9.9 Bus System Option Modbus 48 optional.
9.10 Bus System Option Profibus DP 51 Basic Setup Basic Setup
Config Setup Config Setup
9.11 Bus System Option DeviceNet 54
9.12 Bus System Positioning Control Settings 57 Fig. 9.2 Fig. 9.3
9.13 Option Interrupter Timer 59
9.14 Setting Tool Local Control 61 PRESS THE k KEY.
9.15 Inhibit Operation After Power Loss 61
9.16 Indicator LEDs 62
9.17 Display Language 62
9.18 Default Options 64
10.2 Help Screens 71
10.3 IrDA Diagnostics and Configuration 76
34
9.2 Indication Contacts r1 Contact S1 - Function
S1, S2, S3 and S4
Indication contacts S1 [r1], S2 [r2], S3 [Ol] Open Interlock Active * [LP] Function not available for phases Using the + or - key display the desired
[r3] and S4 [r4] may each be set to trip [Cl] Close Interlock 1 & 2, only for phase 3. For phase loss function.
for any one of the following functions: detection on phase 1 & 2 please use
[lL] Interlock Active monitor relay PRESS THE KEY.
Code Function (as displayed) [AA] Actuator Alarm The displayed function will flash
** [24] Function not available if the 3
[Ht] Thermostat Tripped phase supply is lost. indicating that it has been set.
[CL] Closed Limit
[OP] Open Limit [LP] Lost Phase *
[Po] Position % Open [24] 24V Power Failure **
[rr] Motor Running [bA] Battery Low
[dC] Closing [rP] Relay Parity
S1 Function
[dO] Opening
Close Limit
[d?] Moving The S contact form can be set normally
[HA] Hand Operation open [no] or normally closed [nc]. Contact S1 Configured to Trip
[bL] Moving-Blinker The procedures for setting up contacts at Valve Closed Limit
S2, S3 and S4 are the same as those
[UA] Valve Alarm PRESS THE k KEY.
shown for S1.
[tC] Torque Trip Close (direction)
[tO] Torque Trip Open (direction) Unless specified with order, the
[tt] Torque Trip (any position) default settings for indication
[tl] Torque Trip Mid (travel) contacts are as follows:
[St] Motor Stalled S1 – [CL] Closed Limit [no]
[LS] Stop Selected
S2 – [OP] Open Limit [no]
[Lo] Local Selected
[rE] Remote Selected S3 – [CL] Closed Limit [nc]
[CA] Control Alarm S4 – [OP] Open Limit [nc]
[ES] ESD Active
35
r1 Contact S1 - Value r1 Contact S1
Contact Form
This screen will only display if relay Use the + or - keys to select between
function is set to [P0] Position Open . [nO] Normally Open and [nC] Normally
When the S contact function is set to
Closed .
[P0], the required intermediate position PRESS THE KEY.
value must be set.
The displayed option will flash (stored)
No other contact function requires indicating that it has been set.
a value to be set.
The value can be set from 1% open to
99% open in 1% increments.
Using the + or - key, display the
required value. S1 Contact
Normally Open
PRESS THE KEY.
The displayed value will flash (stored) Contact S1 Configured as a
indicating that it has been set. Normally Open Contact
NOTE: If function [PO] Position Open
is selected and it is configured as a
normally open contact it will make at
the set value with the actuator moving
S1 % Position in the open direction.
25% To access S2–S4
Value Set to Indicate PRESS THE m KEY.
25% Open
PRESS THE k KEY.

36
9.3 Control Mode A1 ESD Action A2 ESD Contact Type A3 ESD Override
Configuration Thermostat
The Control Mode Configuration affects An active ESD signal applied to the The default setting for ESD Contact The default setting for ESD Override
how the actuator will respond under actuator will override any existing or Type is [nO] Normally Open . Thermostat is [OF] No during ESD.
conditions of emergency shut down, applied local or remote control signal. The thermostats remain in circuit and
For actuators set to ESD [nO] Normally
local control, remote control interlocks, ESD can be configured to override the enabled during ESD.
and 2-wire remote control. Also motor thermostat, active interlocks or
Open the ESD Signal must be applied
to activate the ESD command. For ESD The motor thermostats can be bypassed
included is an unseating torque switch local stop selection. Refer to A3, A4
[nC] Normally Closed the signal must be during ESD as a factory set, hard-
bypass function. Unless specified with and A5.
removed to activate the command. wired option only. Contact Rotork for
order, the control mode configuration
The default action under an active ESD Press the + or - key to choose the information.
will be set as shown for default
signal is to stay put [SP] Stay Put . contact type.
configuration on page 63. Danger: Actuator hazardous
Press the + or - key to select the PRESS THE KEY. area certification is invalidated
If it is necessary to change the
configuration follow the instructions in
required ESD action: while the thermostats are
The displayed option (stored) will flash
bypassed.
this section. [OF] Off on ESD indicating that it has been set.
[A3] should be set to reflect the factory
There are 10 configurable control [CL] Close on ESD
set configuration of thermostat bypass.
functions:
[SP] Stay Put on ESD
During an ESD event:
Code Function (as displayed) [OP] Open on ESD
[A3] = [OF] No , thermostats enabled
ESD Contact Type
[A1] ESD Action PRESS THE KEY. Normally Open [A3] = [On] Yes , thermostats bypassed
[A2] ESD Contact Type The displayed option will flash (stored)
indicating that it has been set. Actuator Responds to a Normally
[A3] ESD Override Stat Open ESD Contact (Signal Applied)
[A4] ESD Override Interlocks
[A5] ESD Override Local Stop ESD Override
[A6] Maintain Local Control Stat: No
[A7] 2-wire Remote Priority ESD Action
Close
[A8] Interlocks
[A9] Conditional Control
[At] Torque Switch Bypass.
37
A4 ESD Override A5 ESD Override A6 Maintain A7 2-wire Remote
Interlocks Local Stop Local Control Priority
The default setting for ESD Override The default setting for ESD Override The default setting for Local Actuator The default setting for 2-wire Remote
Interlocks is [OF] No . ESD action will not Local Stop is [OF] No . ESD will not Pushbutton control is self-maintained Priority is [SP] Stay Put . If an open and
override an active interlock applied to override local stop when selected. [On] Yes . closed remote control signal are applied
the actuator. simultaneously the actuator will stay
If an applied ESD signal is required to If non-maintained actuator pushbutton
put (stop if running). Refer to actuator
If an applied ESD signal is required to override local stop causing the ESD control is required (jogging, inching,
wiring diagram or publication E120E.
override active interlocks causing the action as set for A1, press the + or - key. push to run), press the + or - key. The
ESD action as set for A1, press the The display will change to [On] Yes . display will change to [OF] No .
+ or - key. The display will change to
PRESS THE KEY. PRESS THE KEY. Use the + or - key to select the
[On] Yes .
required priority:
The displayed option will flash (stored) The displayed option will flash (stored)
PRESS THE KEY.
indicating that it has been set. indicating that it has been set. [OP] Open
[SP] Stay Put
[CL] Close
PRESS THE KEY.
ESD Override Maintain Local
Local Stop: No Control: Yes
ESD Override
Interlocks: No
2-Wire Remote
Priority: Stay
2-wire Control – Stay Put Priority

38
A8 Interlocks A9 Conditional Control At Torque Switch Bypass
Actuators are delivered with the Where a high level of safety integrity The default setting for Torque Switch
interlock facility disabled [OF] Disabled . is required, Conditional Control can Bypass is [OF] Off , the torque switches
Refer to the actuator wiring diagram or be configured. In this mode two are not bypassed during the unseating
publication E120E for interlock control discreet signals are required for remote movement.
circuits. operation. Remote control will be
To bypass the torque switches during
conditional on both a control signal
To enable remote external interlocks the unseating movement press the +
(open or close) and the appropriate
press the + or - key. or - key.
interlock signal being applied
The display will change to [On] Enabled . simultaneously. Failure of either or a The display will change to [On].
spurious signal will not cause operation.
PRESS THE KEY. PRESS THE KEY.
Interlocks [A8] must be set [On]
The displayed option will flash (stored) Enabled . Interlock signals are not The displayed option will flash (stored)
indicating that it has been set. required for local operation. indicating that it has been set.
The default setting for conditional The torque switches will be bypassed
control is [OF] Disabled . To enable from closed limit to 5% open when
conditional control press the + or - key. opening and from open limit to 95%
The display will change to [On] Enabled . when closing. Bypassing the torque
Interlocks switches makes torque in excess of
Disabled PRESS THE KEY. rated and up to actuator stall available
for unseating a ‘‘sticky’’ valve. Outside
these positions the torque setting will
revert to the values set for [tC] Close
Note: If interlocking is required in only
Torque , see page 27 and [tO] Open
one direction, it will be necessary to
Torque , page 28.
connect a link between the actuator
terminals associated with the other
direction. Refer to wiring diagram.
Conditional
Control: Disabled
Torque Switch
Bypass: Off
39
9.4 Option Extra OE Display Extra Contact
Indication Contacts Set-up Screens
Extra indication contacts S5 [r5], S6 The action of turning on the Extra
[r6], S7 [r7] and S8 [r8] are available as Contact Option makes an additional
an option. series of set-up screens available
Check actuator circuit diagram for
inclusion.
When the Extra Contact Option is
included the set-up procedure and
Extra Contacts Extra Contacts
available contact functions for S5 – S8
Menu: On Menu: Off
are identical to S1–S4 (refer to Section
9.2 page 34).
Press the + or - key to select the Extra
Unless specified with order the default
Contact Option set-up screens [On].
setting for the extra indication contacts
will be as follows: PRESS THE KEY.
S5 [r5] Close limit The displayed option will flash (stored)
S6 [r6] Open limit
PRESS THE m KEY TO ACCESS S5
S7 [r7] Torque trip mid
TO S8 SET-UP DISPLAYS.
S8 [r8] Remote selected
The procedure for setting S5 to
NOTE: If the Extra Contact Option is S8 is the same as that for S1 to S4
not included in the actuator build, any (refer to Section 9.2 page 34).
settings made for S5–S8 will have no
effect on the indication output of the
actuator.
40
9.5 Option CPT [OI] –
4-20mA Indicator
Setting instructions for actuators NOTE: If the actuator has options
including a CPT providing 4-20mA Folomatic and CPT, redefining the
analogue position feedback. CPT, will require the Folomatic to be
recommissioned (refer to Section 9.6
The CPT is an optional extra. It may be Folomatic [OI] page 41).
internally or externally powered.
Check wiring diagram for inclusion and
connection details.
Analog Feedback
CL=4ma OP=20mA
With [HI] Displayed, the CPT operates

Close=4mA , Open=20mA
If Close=20mA , Open=4mA is required, use
the + or - key to change to [LO].
PRESS THE KEY.
indicating that the option has been set.
41
9.6 Option Folomatic – OI Folomatic Feedback FI Analogue
Analogue Control Signal Type
Setting instructions for This instruction lists the Folomatic Before commissioning of the Folomatic Using the + or - key select [ l] Current
actuators including a Folomatic function displays in their sequence and functions can begin, the Folomatic for current input signal or [ U] Voltage
proportional controller for use in assumes that all Folomatic functions are Feedback must be set to suit the for voltage input signal.
to be checked/set. applied set point signal.
analogue valve position control.
The actuator should be selected in Local
The Folomatic is an optional or Stop with the analogue input signal
control device. Check actuator connected to terminals 26(+ve) and
wiring diagram for inclusion. 27(–ve) (refer to wiring diagram).
Analog Signal
Analog Feedback
Before setting the parameters for Type: Current
CL=4ma OP=20mA
Option Folomatic ensure Remote
Control Source [Od] has been With [HI] displayed, a 20mA signal will PRESS THE KEY.
selected to [bo] in Section 9.7. correspond to the valve opening.
If a high input signal is required to indicating that it has been set.
Folomatic set up screens will be correspond to valve closing use the
automatically displayed when the + or - key to change to [LO] CL=20mA . The signal type selected will determine
option is fitted. Refer to actuator wiring what is displayed on the input signal
diagram. PRESS THE KEY. range screen [Fr] Analog Signal .
The displayed option will flash (stored) Press the k key to display:
indicating that it has been set. [Fr] Analog Signal .
If setting [OI] is modified after
commissioning the Folomatic, it will
be necessary to recommission the
Folomatic.
Press the m key to access the
Folomatic set-up display menus.
42
Fr Input FL Valve Position FH Valve Position Fd Deadband
Signal Range LOW Set Point HIGH Set Point Adjustment
Using the + or - key select for required If the actuator hunts or responds
signal within the range of 0–5mA or
APPLY MINIMUM APPLY MAXIMUM unnecessarily to a fluctuating input
volts, 0–10mA or volts or 0–20mA or SET POINT SIGNAL SET POINT SIGNAL signal the deadband must be increased.
volts (i.e. 4–20mA). Using the + or - key select: Using the + or - key select: If more accurate control is required the
deadband may be decreased.
If [FI] is set to current , mA ranges will be [ ] [ ] Closed = valve closed [ ] [ ] Closed = valve closed
displayed. If [FI] is set to Voltage , voltage [00] to [99] = percentage open [00] to [99] = percentage open Use the + or - key to select the
ranges will be displayed. deadband width. Range 00–99
[ ] Open = valve open [ ] Open = valve open
corresponds to 0–9.9% of setpoint
to correspond with the LOW set point to correspond with the HIGH set point signal.
signal. signal.
NOTE: Maximum deadband is 9.9%
of valve stroke. Normally, minimum
Analog Signal deadband should not be less than 1%.
Range: 4-20mA
0–20mA Range Selected

Low Set Point High Set Point
Position: Closed Position: Open
Deadband
1.2%
Analog Signal
Range: 0-20V The displayed value will flash (stored) The displayed value will flash (stored)
indicating that it has been set. indicating that it has been set. PRESS THE KEY.
0-20V Range Selected
Press the k key to display: Press the k key to display: The displayed value will flash (stored)
[FH] High Set Point Position . [Fd] Deadband . indicating that it has been set.
PRESS THE KEY.
indicating that it has been set. [Ft] Motion Inhibit Time .
Press the k key to display:

[FL] Low Set Point Position .
43
Ft Motion Inhibit FA Action On Loss of FF Failsafe Action
Timer Adjustment Set Point Signal
The motion inhibit timer introduces Use + or - key to enable [On] or Failsafe action when [FA] Loss of Signal
a delay in the actuator response to disable [OF] action on loss of set point set to [On] Failsafe only.
a rapidly fluctuating input signal, signal.
preventing unnecessary movement. Use + or - key to select, on loss of
[On] – Failsafe as determined by [FF]. input signal:
Once the system stabilises the actuator
will respond to steady changes in the [OF] – Go to Low SP [Lo] – Go to Low SP position.
input signal as necessary. [SP] – Stay Put
Use + or - key to adjust motion inhibit [Hl] – Go to High SP position.
time in seconds: range 0–99. Normally
it is recommended that motion inhibit
time should not be set to less than 5 Loss of Signal
seconds (refer to note on page 61). Failsafe
Failsafe Action
Go to Low SP
PRESS THE KEY.
Motion Inhibit
Time: 05 seconds
PRESS THE KEY.
NOTE: Failsafe action “ON” will be
effective only for systems using an The displayed option will flash (stored)
offset or live zero signal range, for indicating that it has been set.
PRESS THE KEY. example 4–20mA.
Commissioning of the Folomatic is
The displayed value will flash (stored) [FF] will only be displayed if [FA] has now complete. Remote control may be
indicating that it has been set. been set to [On]. selected.
Press the k key to display: Press the k key to display:
[FA] Loss of Signal . [FF] Failsafe Action .
44
9.7 Remote Control Source Od Remote Control Source
The available forms of remote control The setting of Remote Control Source To change the remote source press the
are listed below: will be determined by the option that + or - key until the required setting is
has been fitted, if any. displayed.
1 - Standard hardwired control
2 - Analogue control-Option Folomatic [rE] Hard-Wired Only : Pushbutton/relay PRESS THE KEY.
3 - Network control including: contact control.
Option Pakscan
[oP] Network : Pakscan, Profibus, indicating that it has been set.
Option Modbus Modbus, Foundation Fieldbus or
Option Profibus DeviceNet control.
Option Foundation Fieldbus
Option DeviceNet [bo] Folomatic : Analogue Proportional
control.
The setting for Remote Control Source
[OF] Remote Disabled : Remote control Control Type
will depend on the type of remote
Hard-wired Only
control required and the option disabled.
specified and fitted. Check actuator Standard Hardwired
circuit diagram for remote control form. Remote Control
45
9.8 Bus System PA Pakscan Node Pb Pakscan
Option Pakscan Address Baud Rate
Setting instructions for actuators The actuator Pakscan Field Control Unit The actuator Pakscan Field Control Unit
including an optional Pakscan Field must be allocated a unique loop node baud rate must be set to the loop baud
Control Unit – check wiring diagram for address. rate. For a Pakscan 2-wire control loop
inclusion. the selected baud rate must be common
The actuator must be in “Loopback” Baud Rate
to the master station and all the field
Before setting the parameters for and isolated from Pakscan loop traffic
control units included in the loop. 2400 Baud
for its address to be set or changed.
Option Pakscan ensure Remote
Loopback can be achieved in two ways: The actuator must be in “Loopback”
Control Source [Od] has been and isolated from Pakscan loop traffic
1. Turn OFF the master station. PRESS THE KEY.
selected to [oP] in Section 9.7. for its baud rate to be set or changed.
(refer to page 44) 2. Isolate the actuator from the The displayed option will flash (stored)
Loopback can be achieved in two ways: indicating that it has been set.
2-wire control loop both in & out.
1. Turn OFF the master station. Press the k key to display:
Using the + or - keys display the
required loop address. 2. Isolate the actuator from the [PF] Aux I/P Mask .
Address to be set within the range
01-240 (01–F0 Hexadecimal). (refer to
table on page 79).
required baud rate.
[01] = 110 baud
Node Address [03] = 300 baud
Hex 01 : Dec 001 [06] = 600 baud
[12] = 1200 baud
PRESS THE KEY.
[24] = 2400 baud
[Pb] Baud Rate .
46
PF Pakscan Remote
Auxiliary Input Mask
The IQ actuator has the facility to accept 4 auxiliary inputs (AUX1–AUX4). These Rules
are used when supplementary remote control or digital auxiliary inputs are required
in addition to the standard control and feedback features incorporated into the 1. Function bit set to ‘‘0’’
Pakscan card. It is also possible to have a combination of both remote control and Any function bit set to ‘‘0’’ indicates that the particular aux input is to be treated as
volt-free inputs to provide, for example, open and close control as well as a high a digital signal for field status reporting, e.g. a level switch or motor running status.
and low tank level alarm indication, supplied via an external transducer.
If the corresponding invert bit is set to a ‘‘0’’, an open contact is reported as a logic
The hexadecimal number displayed under PF can be considered as a ‘‘software "1" and a closed contact is reported as a logic ‘‘0’’ (i.e. this will invert the input).
mask’’. It is this mask that tells the Pakscan card what type of input to expect,
control or input signal, and what form the input will be, normally open or normally If the corresponding invert bit is set to a ‘‘1’’, an open contact is reported as a logic
closed (refer to page 79 for Binary, Hexadecimal and Decimal Conversion Table). "0" and a closed contact is reported as a logic ‘‘1’’ (i.e. this gives a noninverting
input).
To decipher the mask the number needs to be split into two separate hexadecimal
characters, each of which can be sub-divided into 4 binary bits. The first 4 bits 2. Function bit set to ‘‘1’’
represent the function and the second 4 represent the input source (known as Any function bit set to ‘‘1’’ indicates that the particular aux input is to be treated as
invert). Pictorially this can be represented as: a digital command to operate the actuator.
Left side hex character Right side hex character When the corresponding invert bit is set to a ‘‘0’’ this represents an N.C. contact
Aux 4 to 1 (function) AUX 4 to 1 (Invert) as being the command source, i.e. a closing contact de-energises the input and an
Bits 4321 4321 opening contact energises the input.
When used for remote control of the actuator bits 4 to 1 of the function character When the corresponding invert bit is set to a ‘‘1’’, this represents an N.O. contact
have been designated as follows: as being the command source, i.e. a closing contact energises the input and an
opening contact de-energises the input.
Bit 4 (AUX4) – ESD
Bit 3 (AUX3) – Stop (Maintain) 3. ESD Control
When using ESD (aux input 4), the ESD contact mode setting [A2] should be set to
Bit 2 (AUX2) – Close the default value of [nO]. The [A1]–ESD direction setting should be set to either
Bit 1 (AUX1) – Open Open or Close the valve (refer to page 36).
(When used for digital signal inputs they are simply designated as AUX 4 to AUX 1) 4. Stop (Maintain) Control
When energised this will make the Aux input Open/Close/ESD control push-to-run,
(non-maintained).
When de-energised, the Aux input Open/Close/ESD control will be maintained.
47
PF Pakscan Remote PF Pakscan Remote
Auxiliary Input (continued) Auxiliary Input
5. Remote I/P Setting Using the + or - keys display the
Ensure that the correct [Od] Control Type setting is selected (refer to page 44). required mask setting.
For Pakscan this is [oP] Network .
The factory default for [PF] Aux I/P Mask is [OF] 0000 1111 .
Examples
1. The full range of remote controls is needed. Open and Close are NO and ESD Aux I/P Mask
and Stop/maintain is NC. Bits: 0000 1111
Aux I/P 4321 Auxiliary Input Mask [OF]

Function 1111 =F PRESS THE KEY.
Invert 0011 =3 i.e. set [PF] to [F3] The displayed option will flash (stored)
2. Open and close control is required along with 2 inverted digital signal inputs
(Note that with this setting the open and close commands will be maintained.) For Pakscan module positioning settings
[OF], refer to page 57.
Aux I/P 4321
If Pakscan positioning control is
Function 0011 =3 required, PRESS THE m KEY.
Invert 0011 =3 i.e. set [PF] to [33] Display [FL] Low Set Point Position
3. Only an ESD input is needed. The requirement is for push to run control with a (refer to page 57).
NO contact input.
Aux I/P 4321
Function 1100 =C
Invert 1000 =8 i.e. set [PF] to [C8]
48
9.9 Bus System PA Modbus Node Pb Modbus Baudrate
Option Modbus [OP] Address
Setting instructions for actuators The Modbus module must be allocated The Modbus module must be set to the
including an optional Modbus RTU a unique address. RS485 highway baudrate. To set the
module – check wiring diagram for baudrate the Modbus module must be
To set the address the Modbus module
inclusion. isolated from the host by disconnecting
must be isolated from the host by
the RS485 highway or turning off the
disconnecting the RS485 highway or
Before setting the parameters for host device.
turning off the host device.
Option Modbus ensure Remote Using the + or - keys display the
Control Source [Od] has been required address.
required baudrate:
selected to [oP] in Section 9.7. [01] = 110
(refer to page 44). Address to be set within the range (01-
247 to F7 Hexadecimal). If an address [03] = 300 [06] = 600
value outside this range is entered, the [12] = 1200 [24] = 2400
The actuator power must be address set will revert to 01 (for 00) or [48] = 4800 [96] = 9600
cycled for the changes to take effect. F7 (for value above F7). [19] = 19200 [38] = 38400
[57] = 57600 [11] = 115200
Node Address
Hex 01 : Dec 001 Baud Rate
2400 Baud
PRESS THE KEY.

PRESS THE KEY.
indicating that it has been set. The displayed option will flash (stored)
[Pb] Baud Rate . Press the k key to display:
[PF] Aux I/P Mask .
49
PF Modbus Remote
Auxiliary Input
The IQ actuator has the facility to accept 4 auxiliary inputs (AUX1 – AUX4). These Rules
Modbus module. It is also possible to have a combination of both remote control Any function bit set to ‘‘0’’ indicates that the particular aux input is to be treated as
and volt-free inputs to provide, for example, open and close control as well as a a digital signal for field status reporting, e.g. a level switch or motor running status.
high and low tank level alarm indication, supplied via an external transducer.
The hexadecimal number displayed under PF can be considered as a ‘‘software ‘‘1’’ and a closed contact is reported as a logic ‘‘0’’ (i.e. this will invert the input).
mask’’. It is this mask that tells the Modbus module what type of input to expect,
input).
(When used for digital signal inputs they are simply designated as AUX 4 to AUX 1.) 4. Stop (Maintain) Control
When energised this will make the Aux input Open/Close control push-to-run.
When de-energised, the Aux input Open/Close control will be maintained. ESD is
always push to run (non maintained).
50
PF Modbus Remote PP Modbus Parity
Auxiliary Input (continued)
5. Remote I/P Setting Using the or keys display the required Where Modbus parity bit detection is
Ensure that the correct [Od] Control Type setting is selected (refer to page 44). mask setting. used the module must be set with the
parity bit setting of the host.
For Modbus this is [OP] Network .
The factory default for [PF] Aux I/P Mask is [OF] 0000 1111 . required parity bit:
Examples [no] None (no) parity bit
Bits: 0000 1111 [En] Even parity bit
and Stop/maintain is NC.
[Od] Odd parity bit
Aux I/P 4 3 2 1
Function 1 1 1 1 =F
PRESS THE KEY.
Invert 0011 = 3 i.e. set [PF] to [F3]
2. Open and close control is required along with 2 inverted digital signal inputs. indicating that it has been set.
(Note that with this setting the open and close commands will be maintained.) Modbus Parity
Press the k key to display: None
Aux I/P 4 3 2 1 [PP] Modbus Parity .
Function 0 0 1 1 =3 No Parity Bit
Invert 0011 = 3 i.e. set [PF] to [33]
PRESS THE KEY.
3. Only an ESD input is needed. The requirement is for push to run control with a
NO contact input. The displayed option will flash (stored)
Aux I/P 4 3 2 1
Function 1 1 0 0 =C For Modbus module positioning
settings and action on loss of signal
Invert 1000 = 8 i.e. set [PF] to [C8] setting [OF] (refer to page 57).
If Modbus positioning control and
action on loss of communication are
required, PRESS THE m KEY.
Display [FL] Low Set Point Position
(refer to page 57).
51
9.10 Bus System PA Profibus Node
Option Profibus DP [OP] Address
Setting instructions for actuators The Profibus DP module must be
including an optional Profibus DP allocated a unique address.
module – check wiring diagram for
To set the address the Profibus module
inclusion.
must be isolated from the host by Node Address
disconnecting the RS485 highway or Hex 01 : Dec 001
Before setting the parameters for turning off the host device.
Option Profibus ensure Remote
Using the + or - keys display the PRESS THE KEY.
selected to [oP] in Section 9.7. The displayed option will flash (stored)
(refer to page 44). Address to be set within the range indicating that it has been set.
(01-126 to 7E Hexadecimal) (refer to
page 79 for conversion). If an address Press the k to display:
Any settings made locally at value outside this range is entered, the [Pb] Baud Rate .
the actuator may be overwritten by address set will revert to 01 (for 00) or
the host on startup unless the GSD 7E (for value above 7E). [Pb] has no relevance for the
files are locked on the Profibus card. Rotork Profibus DP Mk.2 card.
Refer to publication S420E available
from www.rotork.com Therefore, if the Rotork Profibus DP Mk.2
card is fitted, press the k to display:
[PF] Aux I/P Mask .
The actuator power must be
cycled for the changes to take effect.
52
PF Profibus Remote
Auxiliary Input
Profibus module. It is also possible to have a combination of both remote control Any function bit set to ‘‘0’’ indicates that the particular aux input is to be treated as
The hexadecimal number displayed under PF can be considered as a ‘‘software ‘‘1’’ and a closed contact is reported as a logic "0" (i.e. this will invert the input).
mask’’. It is this mask that tells the Profibus module what type of input to expect,
closed (refer to page 79 for Binary, Hexadecimal and Decimal Conversion Table). ‘‘0’’ and a closed contact is reported as a logic ‘‘1’’ (i.e. this gives a noninverting
input).
Bit 1 (AUX1) – Open open or close the valve (refer to page 36).
(When used for digital signal inputs they are simply designated as AUX 4 to AUX 1.) 4. Stop/Maintain Control
When energised this will make the Aux input Open/Close control push to run When
de-energised, the Aux input Open/Close control will be maintained. ESD is always
push to run (non maintained).
53
PF Profibus Remote PF Profibus Remote
5. Remote Source Setting [Od] Using the + or - keys display the
For Profibus this is [OP] Network .
Examples
Aux I/P Mask
1. The full range of remote controls is needed. Open and Close are NO and ESD
Bits: 0000 1111
Aux I/P 4 3 2 1
Function 1 1 1 1 =F PRESS THE KEY.
(Note that with this setting the open and close commands will be maintained.)
If Profibus positioning control and
Aux I/P 4 3 2 1 action on loss of communication are
Function 0 0 1 1 =3 required, PRESS THE m KEY.
Invert 0011 = 3 i.e. set [PF] to [33] Display [FL] Low Set Point Position
(refer to page 57).
NO contact input.
Aux I/P 4 3 2 1
Function 1 1 0 0 =C
Invert 1000 = 8 i.e. set [PF] to [C8]
54
9.11 Option DeviceNet PA DeviceNet Node Pb DeviceNet Baudrate
Address
Setting instructions for actuators The DeviceNet module must be The DeviceNet module must be set to
including an optional DeviceNet DFU allocated a unique address. the DeviceNet highway baudrate.
Using the + or - keys display the Using the + or - keys display the
inclusion.
required address. required baudrate:
Before setting the parameters for Address to be set within the range (01- [01] = 125 k baud
Option DeviceNet ensure Remote 63 to 3F Hexadecimal). See page 79 for
[03] = 250 k baud
Control Source [Od] has been conversion. If an address value outside
selected to [oP] in section 9.7. this range is entered, the address set [06] = 500 k baud
(refer to page 44). will revert to 01 (for 00) or 3F (for value
above 3F).
Node Address Baud Rate

Hex 01 : Dec 001 500 baud
PRESS THE KEY.

PRESS THE KEY.
The displayed option will flash (stored) indicating that it has been set.
Press the k key to display: [PF] Aux I/P Mask .
[Pb] Baud Rate .
55
PF DeviceNet Remote
Auxiliary Input
are used when supplementary remote control or volt free digital auxiliary inputs are
required in addition to the standard control and feedback features incorporated 1. Function bit set to ‘‘0’’
into the DeviceNet module. It is also possible to have a combination of both remote Any function bit set to ‘‘0’’ indicates that the particular aux input is to be treated as
control and volt free inputs to provide, for example, open and close control as well a digital signal for field status reporting, e.g. a level switch or motor running status.
as a high and low tank level alarm indication, supplied via an external transducer. If the corresponding invert bit is set to a "0", an open contact is reported as a logic
‘‘1’’ and a close contact is reported as a logic ‘‘0’’ (i.e. this will invert the input).
The hexadecimal number displayed under PF can be considered as a ‘‘software
mask’’. It is this mask that tells the DeviceNet module what type of input to expect, If the corresponding invert bit is set to a ‘‘1’’, an open contact is reported as a logic
control or input signal, and what form the input will be, normally open or normally "0" and a close contact is reported as a logic ‘‘1’’ (i.e. this gives a non-inverting
closed. input).
2. Function bit set to ‘‘1’’
characters, each of which can be sub-divided into 4 binary bits. The first 4 bits
Any function bit set to ‘‘1’’ indicates that the particular aux input is to be treated as
represent the function and the second 4 represent the input source (known as
a digital command to operate the actuator.
invert). Pictorially this can be represented as:
When the corresponding invert bit is set to a "0" this represents an N.C. contact
Left side hex character Right side hex character
as being the command source, i.e. a closing contact de-energises the input and an
Aux 4 to 1 (function) AUX 4 to 1 (Invert) opening contact energises the input.
Bits 4321 4321
When the corresponding invert bit is set to a ‘‘1’’, this represents an N.O. contact
When used for remote control of the actuator bits 4 to 1 of the function character as being the command source, i.e. a closing contact energises the input and an
have been designated as follows: opening contact de-energises the input.
3. ESD Control
Bit 3 (AUX3) – Stop (Maintain) When using ESD (aux input 4), the ESD contact mode setting [A2] should be set to
open or close the valve (refer to page 36).
Bit 1 (AUX1) – Open
(When used for digital signal inputs they are simply designated as AUX 4 to AUX 1.)
4. Stop (Maintain) Control
56
PF DeviceNet Remote
For DeviceNet this is [OP] Network .
Examples Aux I/P Mask

1. The full range of remote controls is needed. Open and Close are NO and ESD Bits: 0000 1111
Aux I/P 4 3 2 1
Invert 0011 = 3 i.e. set [PF] to [F3] The displayed option will flash (stored)
2. Open and close control is required along with 2 inverted digital signal inputs.
(Note that with this setting the open and close commands will be maintained.) For DeviceNet module positioning
Aux I/P 4 3 2 1 setting [OF] (refer to page 57).
Function 0 0 1 1 =3
NO contact input.
Aux I/P 4 3 2 1
Function 1 1 0 0 =C
57
9.12 Bus System Positioning FL Bus System Valve FH Bus System Valve Fd Bus System
Control Settings Position at 0% DV Position at 100% DV Deadband Adjustment
If the system control strategy for [FL] Low Set Point Position is the position [FH] High Set Point Position is the position All positioning commands are subject to
Pakscan, Modbus, DeviceNet or to which the actuator will move if a 0% to which the actuator will move if a a deadband tolerance.
Profibus requires intermediate valve command is sent. 100% command is sent.
The deadband sets the expected
travel positioning to a "DV" (Desired
Note that the position set for [FL] will Note that the position set for [FH] will positioning accuracy of the actuator
Value - value corresponding to required
be reported to the host as 0%. The be reported to the host as 100%. The and is dependent on various factors
position), the control parameters in this
actuator display will report % open in actuator display will report % open in including, actuator output speed,
section need to be set. ‘‘Action on Loss
the range set by the limits. the range set by the limits. number of turns and valve torque. If
of Signal’’ parameters apply only to
the deadband is set too low the valve
Modbus and Profibus systems. The default setting is for 0% to be the The default setting is for 100% to be may ‘‘hunt’’ around the set point.
Limited Range Positioning is a selectable Close limit. the Open limit.
option whereby positioning limits, 0% Use the + or - key to display the
Use the + or - key to select the desired Use the + or - key to select the desired required setting:
and 100%, can be at different positions valve position for a 0% command. valve position for a 100% command.
to those used for digital Closed and [00] to [99] – 0% to 9.9% of valve
Open limit commands. Limited range stroke.
positioning can be set using the [FL]
Low Set Point Position and [FH] High Set
Point Position screens.
It should be noted that the actuator will Position: Open
Position: Closed
respond to a digital Open or Close host
command by moving the valve to the Deadband
0% DV = Valve Closed 100% DV = Valve Open 2.5%
set limits irrespective of settings made
for positioning control.
Settings for Deadband and Motion
The displayed option will flash (stored) The displayed option will flash (stored) PRESS THE KEY.
Inhibit Time affect accuracy and
indicating that it has been set. indicating that it has been set.
response time. The displayed option will flash (stored)
Press the k key to display: Press the k key to display: indicating that it has been set.
Any settings made locally at
[FH] High Set Point Position . [Fd] Deadband .
the actuator may be overwritten by Press the k key to display:
the host on startup unless the GSD [Ft] Motion Inhibit Time .
files are locked on the Profibus card.
from www.rotork.com
58
Ft Bus System FA Modbus, Profibus & FF Modbus, Profibus
Motion Inhibit Time (MIT) DeviceNet & DeviceNet
Action on Loss of Signal Failsafe Action
MIT sets the minimum time between Modbus, Profibus & DeviceNet modules Modbus, Profibus & DeviceNet failsafe
successive position commands being can be set to respond on loss of host action when [FA] is enabled.
actioned. It is used in situations to communication by positioning the
Use the + or - key to display the
reduce the number of starts per hour valve. Modbus checks for a loss of
required setting:
and to smooth out fluctuations if general highway communications
continuous positioning is implemented. whereas Profibus & DeviceNet check [Lo] Go to Low SP position.
for a loss of communications addressed
Setting the longest possible time while
specifically to themselves. [SP] Stay put
maintaining acceptable control will
maximise the life of the motorised The default setting is off [OF] and the [HI] Go to High SP position.
valve. default timeout is 255 sec.
Use the + or - key to display the Use the + or - key to display the
required setting: required setting:
[00] to [99] = 0 to 99 seconds. [On] Failsafe as determined by setting [FF] Failsafe Action
[OF] Go to Low SP position. Go to Low SP
PRESS THE KEY.

Motion Inhibit
Time: 05 seconds The displayed option will flash (stored)
Loss of Signal
Failsafe
Failsafe Action Enabled

PRESS THE KEY.
The displayed option will flash (stored) PRESS THE KEY.
Press the k key to display: indicating that it has been set.
[FA] Loss of Signal
(Modbus, Profibus & Devicenet only).
[FF] Failsafe Action .
59
9.13 Option OJ Interrupter Timer Jd Interrupter Timer JC Position in Valve
Interrupter Timer Enabled/Disabled Direction Closing Stroke for
Timer to Start
Setting instructions for actuator When fitted, the timer will be The default for timer direction is [CL], Using the + or - key select the position
including an interrupter timer. made available for operation. timer operation will start in closing for the TIMER TO START WHEN THE
and stop in opening – pulsing VALVE IS CLOSING.
The interrupter timer enables pulsed The Interrupter cannot be operation around the close position.
“stop/start” operation by the actuator [ ] [ ] Closed = valve closed
enabled or disabled using the If pulsing operation is required to stop
as a response to local and remote [00] to [99] = percentage open
Setting Tool. in closing and start in opening – around
control commands. [ ] Open = valve open
the open position, use the + or - key.
This effectively increases the valve
The display will change to [OP] Opening .
stroke time and can be adjusted to
prevent hydraulic shock (water hammer) PRESS THE KEY.
and flow surges in pipelines.
Int. Timer Int. Timer The displayed option will flash (stored) Timer Start
The interrupter timer is an optional Disabled Enabled indicating that it has been set. Position: 25%
extra – check wiring diagram for
inclusion. Interrupter Timer Interrupter Timer Timer Set to Start Pulsing when
Disabled Enabled Closing Valve Reaches 25% Open
When the timer option is available an Timer Start PRESS THE KEY.
additional series of settings can be Closing
accessed by pressing the m key. The displayed option will flash (stored)
NOTE: If the timer option is not Pulsed Operation Around the
available pressing the m key will not Closed Position If the timing is not required in the
access setting. closing stroke select [JC] to [ ] [ ] valve
NOTE: Instructions [JC] and [JO] are closed position.
Press the m key to display interrupter for timer operation around the Closed
timer set-up screens. Press the k key to display:
position. For timing around the Open [JO] Timer Stop Position .
position, read stop for start [JC] and
start for stop [JO].
[JC] Timer Start Position .
60
JO Position in Valve Opening Jn Contactor On Time JF Contactor Off Time JE ESD Override
Stroke for Timer to Stop Interrupter Timer
Using the + or - key select the position Using the + or - key select the actuator Using the + or - key select the actuator The interrupter timer may be overridden
for the TIMER TO STOP WHEN THE run period in the range 1–99 seconds. stop period in the range 1–99 seconds. when the actuator is under ESD signal
VALVE IS OPENING. command. This will mean the actuator
will run to limit without “stop/start”
[ ] [ ] Closed = valve closed action under ESD command.
[00] to [99] = percentage open
Refer to [A1] – [A3] (refer to page 36
[ ] Open = valve open Timer On Time Timer Off Time for ESD settings).
05 Seconds 25 Seconds The default for ESD override interrupter
timer is [OF] No . The interrupter timer
Actuator Run Period Actuator OFF Period
will continue “stop/start” action during
Set for 5 Seconds Set for 25 Seconds
Timer Stop ESD action.
Position: 25% PRESS THE KEY. PRESS THE KEY. If ESD must override the timer use the
+ or - to display [On] Yes .
Timer Set to Stop Pulsing indicating that it has been set. indicating that it has been set.
when Opening Valve
Reaches 25% Open Press the k key to display: Press the k key to display:
[JF] Timer Off Time . [JE] Timer Override ESD
PRESS THE KEY. (refer to note on Page 61).
Timer Override
The displayed option will flash (stored) ESD: No
ESD Override Timer OFF
If timing is not required in the opening
stroke select [JO] to [ ] [ ]. PRESS THE KEY.
Press the k key to display: The displayed option will flash (stored)
[Jn] Timer On Time . indicating that it has been set.
61
Example 9.14 Setting Tool 9.15 Inhibit Operation
Local Control [Or] After Power Loss [OS]
An actuator fitted with the interrupter The default setting for Setting Tool When protection is enabled, on power
timer and set as the example shown in Local Control is [OF] Control Disabled . The default setting for this up if a low battery is detected, the
these instructions would operate at: protection option is disabled [OF]. actuator will inhibit electrical operation
To enable Setting Tool Control press the When disabled it is important
+ or - key to select [On]. and display Power Loss Inhibit via
Rated speed from full Open to 25% that the actuator is not manually actuator alarm display (refer to page 5)
Open. operated during a power failure
PRESS THE KEY. and the monitor relay will de-energise.
1/6 if the battery is low as changes in Limits must reset and the battery
rated speed from 25% Open to Fully
The displayed option will flash (stored) position cannot be tracked - refer replaced – refer to page 66.
Closed and from Fully Closed to 25%
indicating that it has been set. to page 6 for battery level status
Open.
display. Should this occur the
With the red control selector in Local, Press the k key to display:
Rated speed from 25% Open to Fully limits must be reset before electric
the Setting Tool control keys are active [OH] Close Colour .
Open. operation takes place- refer to LC/
(refer to page 17). LO page 27. Locking the hand auto
lever can prevent manual operation
- refer to Section 3.1, page 3.
Note
I-R Tool Control
On
With a Folomatic option fitted and
the Interrupter Timer enabled, the Local Setting Tool Control Enabled Power Loss
Folomatic Motion Inhibit Timer must Inhibit : Off
be adjusted to the same time as that Vandal resistant actuators ONLY
set for the Interrupter Timer “contactor (red/black selectors not supplied). The protection may be enabled by using
off”. For control, the selection of [Or] Vandal the + or - key to select [On]
Failure to do so will cause the actuator Resist is as follows:
response to defer to the lower time
PRESS THE KEY.
[On] Local Only .
which may cause control or process The displayed option will flash (stored)
problems. [OF] Control Disabled . indicating that it has been set.
For “ON” and “OFF” times in excess of [rE] Remote Only .
99 seconds apply to Rotork.
62
9.16 Indicator LEDs OH Close LED Colour OU Mid-Travel LED 9.17 Display Language
The colour of the LEDs on the IQ display The default close limit position indicator The default for mid travel position
are user configurable. These menu colour is [gr] Green . indicator colour is [OF] Off . UL
sceens allow you to set the Close LED Language
If red indication is required at the close If mid-travel LED indication is required,
colour and the Mid-Travel LED being
limit position, press the + or - key. press the + or - key.
on or off. The default display text language is
The display will change to [rE] Red . The display will change to [On] On . English. If the language was specified
at time of order the actuator will be
PRESS THE KEY. PRESS THE KEY. despatched with the specified language
The displayed option will flash (stored) The displayed option will flash (stored) set.
indicating that it has been set indicating that it has been set.
Press the + or - keys to view alternative
languages.
Available standard languages:
German Deutsch
Close Colour Mid-Travel LED
Green Off French Français
Spanish Español
Press the k key to display: Press the k key to display: Depending on the specified language,
[OU] Mid-Travel LED . [UL] Language . only English and one other may be
supplied with the actuator.
Language
English
63
9.18 Default Options
[d1] and [d2]
All IQ functions are configured to a set of Rotork default (standard) settings before Rotork standard [d1] Default settings for IQ:
despatch, see the table opposite. When requested, alternative settings specified
with the order will be used. When site commissioning takes place, entered settings Function [d1] Default Setting
overwrite Rotork defaults and these ‘‘current’’ settings are used for operation along [P?] Password Unaffected – will remain as set
with the remaining unadjusted defaults. [Ir] IrDA – Insight [On] IrDA Enabled
Should difficulty be encountered during commissioning the default settings can be
reinstated, returning the actuator configuration to its original manufactured state. Basic Settings
Site commissioning must then begin again. [C1] Close Direction [C] Clockwise
There are two levels of default: [C2] Close Action [Cl] Close on Limit
d1 Rotork standard or customer specified Basic and Configuration Settings. [C3] Open Action [Cl] Open on Limit
[tC] Close Torque [40] 40% of rated
d2 Limit positions only – factory set limits.
[tO] Open Torque [40] 40% of rated
NOTE: Settings associated with control options Folomatic, Pakscan, Modbus
Profibus and Foundation Fieldbus are not affected by d1 or d2. Configuration Settings
Functions will remain as set. [r1] Indication Contact S1 [CI]/[nO] Close, Normally Open
If d1 is entered, all Basic and Configuration Settings except limit positions [r2] Indication Contact S2 [OP]/[nO] Open, Normally Open
will return to their default setting. See the table opposite for Rotork
[r3] Indication Contact S3 [CI]/[nC] Close, Normally Closed
standard settings. Basic settings (except limits) and Configuration Settings
must then be checked and reset as required (refer to Basic Settings page 22 [r4] Indication Contact S4 [OP]/[nO] Open, Normally Closed
and Configuration Settings page 31). [A1] ESD Action [SP] Stay put on ESD
If d2 is entered the limits will be reset, with the actuator positioned at 50%. [A2] ESD Contact Type [nO] Normally Open (make for ESD)
Limits must then be reset to the suit the valve (refer to Basic Settings page 20).
[A3] ESD Thermostat Override [OF] Thermostats Active during ESD
[A4] ESD Override Interlocks [OF] Interlocks Active during ESD
[A5] ESD Override Local Stop [OF] Local Stop Active during ESD
[A6] Maintained Local Control [On] Maintains in Local Control
64
[d1] and [d2] cont.
Rotork standard [d1] Default settings continued: The Rotork standard default settings are subject to change without notice.
If specified with order, [d1] settings will be configured as requested.
Function [d1] Default Setting
To reinstate [d1] settings, with [d1] displayed.
[A7] 2-wire Remote Control [SP] Stay Put on 2-wire signal
[A8] Interlocks [OF] I/L function disabled PRESS THE KEY.
[A9] Conditional Control [OF] Function disabled
The setting bars will flash, indicating the [d1] default settings have been reinstated.
[AE] Torque Switch Bypass [OF] Function disabled
[OE] Option Extra Indication Contacts [OF] Unless fitted. See wiring diagram To reinstate factory set limits (actuator positioned at 50%) with [d2] displayed,
[OI] Option CPT [HI] 4mA at Closed PRESS THE KEY.
[Od] Remote Source [rE] Unless option fitted
(refer to 9.7 page 44.) The setting bars will flash, indicating the [d2] default limits have been reinstated.
[OJ] Option Interrupter Timer [OF] Unless fitted. See wiring diagram Limits must now be reset. Refer to page 29.
[Or] Setting Tool Local Control [OF] Setting Tool Control disabled
[OS] Power Loss Inhibit [OF] Protection off
Option Extra Indication Contacts (when fitted) - refer to wiring diagram

[r5] Indication Contact S5 [CI]/[nO] Close, normally open Restore Config Reset Limits to
Range 25 Turns
[r6] Indication Contact S6 [OP]/[nO] Open, normally open
[r7] Indication Contact S7 [tI]/[nO] Torque Trip Mid Travel,
normally open [d1] Displayed [d2] Displayed
[r8] Indication Contact S8 [rE]/[nO] Remote Selected,
normally open
65
10 Maintenance, Monitoring
and Troubleshooting
Maintenance Routine maintenance should include WARNING: Battery Replacement
Every Rotork actuator has been fully the following: If the actuator is located within a
The battery holder in the actuator
tested before dispatch to give years of hazardous area permission must be
* Check actuator to valve fixing bolts gearcase also protects the user from
trouble-free operation providing it is obtained in the form of a ‘‘hot work
for tightness. the hazardous live connections
installed, sealed and commissioned in permit’’ or other local regulation before
accordance with the instructions given * Ensure valve stems and drive nuts are inside the actuator and therefore it removal and/or replacement of the
in this publication. clean and properly lubricated. must not be damaged. The actuator battery.
must be isolated or disconnected
The IQ actuator’s unique double sealed, * If the motorised valve is rarely Removal of the battery with the main
non-intrusive enclosure provides operated, a routine operating if the battery holder has to electrical power switched off will result
complete protection for the actuator schedule should be set up. be removed from the actuator in stored Datalogger records time
components. gearcase. reference being lost for the duration
* Replace actuator battery every
A unique circuit has been incorporated when there is no mains and battery
Covers should not be removed for 5 years.
into the battery function of the IQ, power. It is therefore recommended
routine inspection as this may be
* Check the actuator enclosure for effectively reducing the overall drain that the battery is replaced with the
detrimental to the future reliability of
damage, loose or missing fasteners. and significantly increasing the battery main electrical supply to the actuator
the actuator.
life. switched on.
* Ensure there is not an excessive
The electrical control module cover is
build up of dust or contaminant If main electrical power is not available
bonded by the Rotork quality control In normal circumstances
on the actuator. or if main power has been switched off
seal. It should not be removed as the battery replacement interval should while the battery was discharged, it is
module contains no site-serviceable * Check for any loss of lubricant. not exceed 5 years. Ambient recommended that the actuator limits
components. temperature and plant operating be checked after battery replacement
All electrical power supplies to the
The Actuator Battery conditions may affect battery life. (refer to Section 8 Commissioning Basic
The battery supports the actuator Settings, page 22).
actuator must be isolated before any Battery level status is indicated by an
position updating circuits and the
maintenance or inspection is carried icon on the actuator display, refer to
position (LCD) display when the main Battery Removal
out, except replacement of the battery. Section 3.4 Alarm Indication (refer to
power supply is turned off. It ensures The actuator must be selected to Stop
Electrical supplies must be isolated the current position is updated and page 5).
using the red selector (refer to page 3).
before actuator covers are removed displayed when manual operation takes If the battery icon is displayed the Access to the battery is via a labelled
refer to Battery replacement place with the main power turned off. battery must be replaced. sealing plug situated on the main
instructions. gearcase near the handwheel hub.
The battery is not required to retain any
actuator settings.
66
and Troubleshooting cont.
Use an 8mm Allen key to remove the If in doubt regarding the correct battery Torque and Position Monitoring
sealing plug, ensuring the ‘‘O’’ ring seal type, contact Rotork. The IQ range of actuators incorporate
remains on the plug. Disconnect the real time, instantaneous Torque &
battery wiring loom from the battery Fitting Replacement Battery Position monitoring as standard.
terminals. Using the black pull strap, lift Fit the pull strap around the
the battery out of the rubber sealing replacement battery and insert into Torque & Position can be used to
pocket. the rubber sealing pocket. Reconnect monitor valve performance during Torque = 19%
the battery wiring loom to the battery operation. The effect of process
terminals. Refit the battery sealing plug changes (differential pressure etc.) can
ensuring ‘‘O’’ ring is in good condition be evaluated. Tight spots in valve travel
and correctly fitted. Hand tighten can be pinpointed as well as gauging Example shows 19% (of rated) torque
sealing plug using an 8mm Allen key. torque developed through stroke for at 50% open position. Display torque
torque value setting (refer to pages range: [00] to [99]% of rated torque
Oil 27, 28). in 1% increments. For values of torque
Unless specially ordered for extreme Using the Setting Tool, the display can above 99% the display will indicate [HI].
climatic conditions, Rotork actuators be set to indicate Torque and Position Display position range:
are dispatched with gearcases filled as follows:
with SAE 80EP oil which is suitable for [ ] [ ] = valve closed
Fig. 10.1 ambient temperatures ranging from With the actuator displaying Current
–22°F / –30°C to 160°F / 70°C. Position, using the Setting Tool,
Battery Types [ ] = valve open
For European hazardous area certified IQ actuators do not require regular PRESS THE m KEY.
For a stationary actuator the display
actuators (ATEX) use an Ultralife U9VL oil changes (refer to Weights and The lower display will show the torque will indicate the actual torque value as
lithium manganese dioxide battery only. Measures Section 11, page 78). value as a percentage and a graphical applied by the actuator.
For FM and CSA certified enclosures use representation in the form of a bar
graph. To keep the torque & position display
an Ultralife U9VL lithium manganese active press the + or - keys. The display
dioxide battery. Equivalent, UL will remain active for approximately 5
recognised, batteries may be used. minutes from the last key operation.
For watertight (WT) actuator enclosures
use an Ultralife U9VL lithium
manganese dioxide battery or any
equivalent 9V battery.
67
Torque – Reference Profile Storing a Reference Profile Enter the correct password and press Pressing the key stores the last
IQ text display models only. the key, "Password Correct” measured “reference” close-open and
The location of torque reference profile
should display briefly and the setting open-close torque profiles within the
Only visible when in Setting Mode. See [tP] screen is shown below:
bars appear. datalogger.
Section 7, page 20.
Press the k arrow key 3 times to Press the k and m keys together to
This feature allows the user to store a 50 display the [tP] screen: return to the positional display.
reference torque profile, which can be
used to plan and determine periodic m The reference profile along with current
maintenance. 50 profiles can be viewed and analysed using
Torque
Torque IQ Insight software as shown in Fig 10.2.
After commissioning has taken place
and the process is running under m Torque Profile IQ Insight is available free, visit
normal conditions, a profile of the “as P? k PC k Ir k tP Press To Set www.rotork.com
commissioned” torque measurement
over the whole stroke can be taken m
and stored in the Datalogger. The cr k Configuration Settings
stored torque reference profile can be
compared with later torque profiles m
using Rotork Insight in order to Basic Settings
determine changes in performance of
the valve and/or process over time or
under different conditions. Each actuator is supplied without a
reference profile stored. To store a
reference profile, electrically stroke the
actuator under normal process conditions.
Once the reference stroke (close to
open / open to close) is complete stop
the actuator.
Using the supplied Setting Tool, press
the m arrow key twice to display the
password screen. Refer to section 7
page 20. Fig. 10.2
68
10 Maintenance, Monitoring 10.1 Setting Tool Pro
and Troubleshooting cont. Download & Upload
Troubleshooting (Refer to Section 3.3 page 4 – The Setting Tool Pro Download & Download/Upload Menu structure
The IQ range of actuators is the world’s Actuator Display). Upload
first that can be commissioned and Setting Tool Pro includes a feature
If the display is blank the actuator
interrogated without removing electrical which allows the user to extract
battery must be replaced and the limits dL 01 dC 01
covers. Help Screen diagnostics enable and store IQ actuator configuration
of travel reset (refer to Section 10,
fast and complete fault finding to be and datalogger files within the Tool.
page 65 – The Actuator Battery). Extract Extract
carried out. Stored files can be viewed using a PC
Datalogger Configuration
running IQ Insight ©. Using This tool,
With power off, the actuator display stored configuration files can also be
is not backlit. Position indicator uploaded back to IQ actuators in order
lamp not illuminated. to replicate a setup for multiple units
With mains power on, the actuator’s (limits must be set individually).
display should be backlit (refer to
Section 3.3 page 4 – The Actuator IQ Insight is available free from
Display). www.rotork.com P? Id
N Actuator password
Check that 3 phase supply is available Using the new features
and is of the correct voltage as stated entered?
Datalogger and configuration files
on the actuator nameplate. Measure can be extracted and stored in the
voltage phase to phase across terminals Tool without entering a password. For
1, 2 and 3 of the actuator terminal uploading configuration files from Tool
bung. to actuator, the actuator’s password Y
must first be entered correctly – see
With power Off, the actuator does section 7, page 20 for details.
not display position.
With mains power off the actuator UI 01
Accessing the menus
battery supports position indication The download/upload menus are Upload
liquid crystal display only. accessed when the Setting Tool Pro Configuration
download key m is pressed. IrDA
communication is initialised, the green
LED in the tool window will flash. The
user then has 30 seconds to “connect”
to the actuator.
69
10.1 Setting Tool Pro
Download & Upload cont.
Downloading and storing IQ Downloading and storing IQ Note. IQ actuators with non text
Datalogger Files Configuration Files displays show code/symbols only.
Press the m Key Press the m Key The screen will default to Memory
The green LED visible in the setting Tool Extract Log The green LED visible in the setting Tool
Location 01. There are a total of
Extracting Data ten memory locations available for
window will start flashing. window will start flashing.
Configuration Files, which are selected
Point the Tool at the actuator Display Extracting Log screen Point the Tool at the actuator Display by pressing the + or – keys.
Once communication has been Once communication has been When the required location has been
successfully established, the Extract Note. IQ actuators with non text successfully established, the Extract selected, press the key to initiate
Datalogger screen will be displayed: displays show code/symbols only. Datalogger screen will be displayed: the extraction. The following screen will
The extraction takes approximately 35 be displayed:
seconds for a full datalogger (2 minutes
for non text displays). After a successful
extraction, the screen will revert to
Extract Log
the Extract Log screen. If during the Extract Log
downloading an error is encountered, Memory Loc: 01 Extract Config
Memory Loc: 01 Extracting Data
[dL Er] will be displayed along with
Extract Datalogger screen Error , wait for the screen to revert to Extract Datalogger screen
[dL 01] and try again. Extracting Configuration screen
Note. IQ actuators with non text Note. IQ actuators with non text
Note. IQ actuators with non text
displays show code/symbols only. The action of downloading the displays show code/symbols only.
displays show code/symbols only.
actuator datalogger file will
The screen will default to Memory automatically download the
PRESS THE k KEY. The extraction takes approximately 3
Location 01. There are a total of configuration file to the Tool. The following screen will be displayed: seconds. After a successful extraction,
four memory locations available for the screen will revert to the Extract
dataloggers, which are selected by configuration screen. If during the
pressing the + or – keys. downloading an error is encountered,
When the required location has been [dL Er] will be displayed along with
selected, press the key to initiate Extract Config Error, wait for 5 seconds until the screen
Memory Loc: 01 reverts to [dC 01] and try again.
the extraction. The following screen will
be displayed: Extract Configuration screen
70
Uploading a configuration File to an PRESS THE k KEY. Note. IQ actuators with non text
IQ actuator displays show code/symbols only.
The download configuration screen will
be displayed: [dC 01] The writing process take approximately
12 seconds to complete, after which
Note: Actuator must be set to PRESS THE m KEY. the screen reverts to the Uploading
Local when writing configuration
The upload configuration screen will be Configuration screen. If during the
data.
displayed: writing process an error is encountered,
Warning: After uploading a Error , wait for 5 seconds until the screen
configuration file from the tool reverts to [UC 01] and try again.
to the actuator, the actuator basic
and configuration set up will be a
duplicate of the file set up. Write Config
Memory Loc: 01
Refer to sections 8 & 9.
Open and close limit positions and Upload Configuration screen
current position are not copied
and must be set on each individual Note. IQ actuators with non text
actuator. Refer to section 8. displays show code/symbols only.
For access to the Upload Configuration Using the + or – keys, select the
screen, the actuators password must memory location where the required
first be set correctly, see section 7. configuration file is stored and press
the key, the following screen will
Press the m Key be displayed:
The green LED visible in the setting Tool
window will start flashing.
Point the Tool at the actuator Display
Once communication has been successfully Write Config
established, the download datalogger Writing Data
screen will be displayed.[dL 01]
Uploading Configuration screen
71
10.2 Help Screens H1 Factors Inhibiting
Electrical Operation
H1
With the actuator powered up and For troubleshooting, access the BATTERY LOW ON POWER UP
Local or Stop selected, eight Help following Help Screens and refer to Bar ON = Low battery detected On
Screens can be accessed using the text: Power Up.
Setting Tool (refer to Fig. 9.1 page 32
If [OS] is selected [On] (default is [OF])
Phase Position
H1 – Factors inhibiting electrical
for their location). Loss Error
operation. the actuator operation will be inhibited
With Remote selected press the m when powered up with a discharged
key on the Setting Tool twice. The Help H2 – Monitor battery level and ESD
battery (refer to [OS] page 61).
Screens will be displayed. control input.
The battery should be replaced at the
Each screen uses bars to indicate H3 – Monitor the position limit and
Local earliest opportunity (refer to page 65).
the status of a particular control or actuator power supply status. Controls
indication function. Each bar reacts to H4 – Monitor remote control inputs to Error LOCAL CONTROLS ERROR
changes in the status of its actuator the actuator. Battery Low Bar ON = Invalid Local Control
function by turning ‘‘on’’ or ‘‘off’’. on Signals Detected.
H5 – Monitor remote interlocks local Power-up
control inputs and motor For example if a Local Open and Close
thermostats. Help Screen 1 signal is detected at the same time this
would be classed as an invalid or fault
H6 – Monitor torque switch status and POSITION ERROR condition.
IR Setting Tool communication for Bar ON = Current Position Error
vandal proof applications. Present. PHASE LOSS
H7 – Monitor travel limits, centre During power up the actuator position Bar ON = Phase Lost (3 Phase
column and position limit status. processor compares the current position Actuators Only).
H8 – Monitor the actuator’s position- to that stored in the Eeprom. If there is Loss of third monitored power supply
sensing devices. a discrepancy this is shown as a current phase connected to actuator terminal 3.
position error.
H9 – Rotork use only.
Re-setting of both actuator limits
Help screen bars shown should now be carried out (refer to
are undefined and may page 29).
be ON, OFF or flashing.
72
H2 Battery Level and H3 Factors Inhibiting H4 Remote Control
ESD Control Input Electrical Operation Inputs
H2 H3 H4
LOW BATTERY
Bar ON = Battery level low.
Bar OFF = Battery OK.
ESD Clockwise Remote Remote
Active Bar ON when the battery is low but still Limit Maintain 2 Open 1
able to support the necessary actuator
functions. Anti
Low Clockwise ESD 2 Remote
Battery The battery should be replaced at the Limit Close 1
earliest possible opportunity.
Battery Inhibit Remote
Discharged ESD SIGNAL ACTIVE Close 2 ESD 1
Bar ON = ESD Signal is present.
When applied, an Emergency Shutdown Remote Remote
Help Screen 2 Help Screen 3 Open 2 Maintain 1
Signal will override any existing local
or remote control signal, causing the Help Screen 4
BATTERY DISCHARGED CLOCKWISE LIMIT
actuator to respond in the direction
Bar ON = Battery Discharged. Bar ON = Actuator has reached All remote signals designated with ‘1’
selected for ESD.
clockwise limit of travel. are standard hard wired remote inputs.
Bar ON when the battery is no longer
The ESD function will be determined
able to support actuator functions ANTI-CLOCKWISE LIMIT When a Pakscan, Profibus or
by the settings on Control Mode
under loss of power conditions. Bar ON = Actuator has reached Foundation Fieldbus card is fitted,
Configuration screens [A1] to [A5]
The battery must be replaced (refer to (refer to Section 9.3 page 36). Anti-clockwise limit. remote control inputs are designated
Section 10 page 65) and limit positions with a ‘2’.
The actuator will not respond to any INHIBIT
reset (refer to [LC] and [LO] page 29).
local or remote control while an ESD Bar ON = Actuator inhibited. REMOTE OPEN 1
signal is maintained. Bar OFF = Remote Open Signal
Possible Causes: Present.
Phase Loss (3 phase only).
Power Loss Inhibit (page 61).
Internal Failure.
continued...
73
H4 Remote Control H5 Remote Interlocks,
Inputs continued Local Control
Inputs, & T/stat
H5
REMOTE CLOSE 1 CLOSE INTERLOCK THERMOSTAT TRIPPED
Bar OFF = Remote Close Signal Bar ON = Close Interlock Active. Bar ON = Thermostat tripped.
Present. (Actuator disabled)
Local Stop The actuator motor is protected by
ESD 1 not Open
Unauthorised Close electrical operation thermostats.
Bar OFF = ESD signal present. Selected Interlock
can be prevented by interlocking
Should the motor become overheated
the actuator (Close) control with an
REMOTE MAINTAIN 1 Thermostat Close the thermostats will trip and the
external interlock contact.
Bar OFF = Remote Maintain Tripped Interlock actuator will stop. On cooling the
signal present. If external interlocks are not required thermostat will automatically reset,
Bar ON = Remote Maintain not Local Open Local not the interlock function must be selected enabling operation. See the actuator
present and/or Remote Stop not Present Selected OFF. nameplate for the motor rating.
active.
Local Close Remote REMOTE NOT SELECTED LOCAL STOP NOT SELECTED
REMOTE OPEN 2 not not Bar ON = Remote control not selected. Bar ON = Local Stop not selected.
Bar OFF = Remote Open signal Present Selected Bar OFF = Remote control selected. Bar OFF = Local stop selected.
present from BUS option pcb. Help Screen 5
LOCAL CLOSE NOT PRESENT LOCAL NOT SELECTED
REMOTE CLOSE 2 OPEN INTERLOCK Bar ON = Local Close signal not present. Bar ON = Local control not selected.
Bar OFF = Remote Close signal Bar ON = Open Interlock Active. Bar OFF = Local Close signal present. Bar OFF = Local control selected.
present from BUS option pcb. (Actutator disabled)
LOCAL OPEN NOT PRESENT
ESD 2 Unauthorised Open electrical operation Bar ON = Local Open signal not present.
Bar OFF = ESD signal present can be prevented by interlocking Bar OFF = Local Open signal present.
from BUS option pcb. the actuator (Open) control with an
REMOTE MAINTAIN 2 If external interlocks are not required
Bar OFF = Remote Maintain the interlock function must be selected
signal present from BUS option OFF.
pcb.
74
H6 Torque Switch Status & IR H7 Travel Limits, Centre
Setting Tool Comms for Column & Remote
Vandal Proof Applications Indication Outputs
H6 H7
TORQUE SWITCH TRIPPED IR OPEN SIGNAL NOT PRESENT
Bar ON = Torque switch tripped. Bar OFF = IR Open signal present.
IR Remote When the actuator generates a value IR CLOSE SIGNAL NOT PRESENT
Control not Open
Selected of torque equal to that set for Open Bar OFF = IR Close signal present. Relay 4 Limit
(when opening) or Close (when closing)
IR Local Local it will stop, protecting itself and the IR LOCAL CONTROL DISABLED
Control Controls Relay 3 Close
Disabled not Fitted
valve from damage. This feature is Bar OFF = IR Local control enabled.
known as Over Torque Protection.
To operate the actuator locally with
IR Closed Once a torque trip has occurred further the IR Setting Tool refer to the option Actuator
Signal not operation IN THE SAME DIRECTION is selection screen [Or] Section 9.14,
Relay 2 Moving
Present prevented. page 61.
IR Open Torque This ‘‘latching’’ of the event protects Relay 1
Signal not Switch [Or] must be selected to [On].
Present Tripped the actuator and valve from repeated Help Screen 7
“hammering” against the obstruction IR REMOTE CONTROL NOT
Help Screen 6 as a response to a maintained control OPEN LIMIT
SELECTED
When actuators are supplied for signal. Bar OFF = IR Remote control Bar ON = Actuator has reached
Vandal Proof applications the local To ‘‘de-latch’’ the actuator it must be selected (vandal-proof units only). open limit.
control knobs are removed to prevent reversed. When actuator is supplied without local CLOSE LIMIT
unauthorised operation.
(For actuator torque adjustment, refer controls for vandal proof applications Bar ON = Actuator has reached
The local control functions are then to [tC ] and [tO] pages 27 and 28) the option selection screen [Or] must Close limit.
carried out by using the Infra-red be set to [rE] for
Setting Tool. ACTUATOR MOVING
Remote operation (refer to Section 9.14
page 61). Bar ON = Actuator moving.
LOCAL CONTROLS NOT FITTED
Bar OFF = Local controls fitted SWITCH CONTACTS S1, S2, S3, S4
(standard). Bar ON = S contact is close circuit.
Bar ON = Local controls not fitted
(vandal proof). Bar indication is real time and reactive
(refer to Section 9.2 [r1] page 34 for
configuration of ‘‘ S’’contacts).
75
H8 Actuator Position
Sensing Devices
H8
When the motor is running, ON and
OFF bit duration should be equal.
For the two sensors, A and B, correct
Position
Sensor A
operation is indicated by the following
truth table.
Position To observe this function, select manual
Sensor B operation and turn the actuator
handwheel clockwise, starting with all
sensors OFF:
CLOCKWISE 30 Deg.
Help Screen 8
Sensor B 0 1 1 0 0
POSITION SENSOR A
Senses output rotation. Used for Sensor A 0 0 1 1 0
the position sensing circuit. Correct
operation of the sensor is indicated by
the bar being ON (and OFF) 12 times
per output revolution. When the motor
is running, ON and OFF bit duration
should be equal.
POSITION SENSOR B
Senses output rotation. Used for
per output revolution.
76
10.3 IQ Infrared
Diagnostic and Configuration
IQ actuators include an IrDA ® (Infrared To enable communication with IQ
Data Association) interface as standard, Insight the actuator IrDA interface The use of a notebook PC
allowing non-intrusive diagnostics, must be enabled. or PDA with actuators located in
analysis and configuration. hazardous areas will be subject
The default setting for IQ IrDA is [On], to local regulations. It is the
IQ Insight software tool for PC and IQ enabling IrDA. responsibility of the user to seek
Pocket Insight for PDA (Personal Digital guidance and permission.
To disable IrDA and prevent IrDA access,
Assistant) have been developed to
use the + or – key. The display will The Rotork Setting Tool and Setting
enable the actuator configuration and
change to [OF]. Tool Pro are certified Intrinsically
onboard datalogger to be reconfigured
and analysed. A PC running IQ Insight Safe (IS) and therefore can be used
software or PDA running IQ Pocket in defined hazardous areas (refer to
Insight can be used to interrogate the PRESS THE KEY. page 17).
actuator via non-intrusive infra red IrDA The displayed option will flash (stored)
communication. Visit www.rotork.com indicating it has been set.
for information.
Alternatively, the intrinsically safe
Rotork Setting Tool Pro allows the
user to extract and store IQ actuator
configuration and datalogger files
within the Tool. Stored files can be IrDA Comms
uploaded over an IrDA –USB interface Enabled
to a PC running Rotork IQ Insight
where they can be viewed, analysed IQ Insight and IQ Pocket Insight
and stored in a safe, clean environment. software are available free of charge
Using the Setting Tool Pro, actuator set from the Rotork web site,
up can be configured on the PC, stored www.rotork.com.
in the tool, transported to the actuator A kit is available from Rotork, which
and uploaded. The tool can transfer includes an IrDA-USB adapter and
the same configuration to multiple drivers for connection to a PC. The Kit
actuators where actuator setup is the also includes IQ Insight software. PDA
same. Refer to page 68. communication is via the internal IrDA port.
77
10.4 Environmental
End user advice on disposal at end of life of the product
Subject Definition Remarks / examples Hazardous Recyclable EU Waste Code Disposal

Batteries Lithium IQ/IQT standby battery Yes Yes 16 06 06 Will require special treatment before
Alkaline Setting tool Yes Yes 16 06 04 disposal, used specialist recyclers or
Lead Acid Battery Failsafe Units Yes Yes 16 06 01 waste disposal companies

Electrical & Printed circuit boards All Products Yes Yes 20 01 35 Use specialist recyclers
Electronic Wire All Products Yes Yes 17 04 10
Equipment
Glass Lens/Window Cenelec Qualified IQ/IQT. A Range Prism No Yes 16 01 20 Use specialist recyclers

Metals Aluminium Gearcases and covers most products No Yes 17 04 02 Use licensed recyclers
Copper/Brass Wire, IQ columns (not all sizes), motor windings No Yes 17 04 01
Zinc IQ clutch Ring and associated components No Yes 17 04 04
Iron/Steel Gears and Gearcases (A Range and larger IQ) No Yes 17 04 05
Mixed Metals IQ motor rotors No Yes 17 04 07

Plastics Glass filled nylon Covers, IQT clutch components, electronics chassis No No 17 02 04 Disposal as general comercial waste
Unfilled Gears No Yes 17 02 03 Use specialist recyclers

Oil Mineral & Kerosene Mixed Gearbox lubrication Yes Yes 13 07 03 Will require special treatment before
Mineral Gearbox lubrication Yes Yes 13 02 04 disposal, use specialist recyclers or
Food Grade Gearbox lubrication Yes Yes 13 02 08 waste disposal companies

Rubber Seals & Orings Cover and shaft sealing Yes No 16 01 99 May require special treatment before
disposal, use specialist waste disposal
companies
In all cases check local authority regulation before disposal

78
11 Weights and Measures
Oil Actuator Size Nett Weight Oil Capacity

Unless specially ordered for extreme kg/lbs litres/pt.-US
climatic conditions, Rotork actuators
are dispatched with gearcases filled IQ10 32/70 0.3/0.63
with SAE 80EP oil suitable for ambient IQ12 32/70 0.3/0.63
temperatures ranging from –22°F/
–30°C to 160°F/70°C. IQ18 32/70 0.3/0.63
NOTE: Excludes second stage gearbox IQ20 52/115 0.8/1.7

if fitted. IQ25 52/115 0.8/1.7
Food grade lubricating oil is available as IQ35 75/165 1.1/2.3
an alternative: contact Rotork.
IQ40 200/441 7.5/15.8
IQ70 215/474 7.0/14.7
IQ90 230/507 7.0/14.7
IQ91 220/485 7.0/14.7
IQ95 230/507 7.0/14.7
79
BHD Binary, Hexadecimal and
Decimal Conversion Table
BINARY HEX DEC BINARY HEX DEC BINARY HEX DEC BINARY HEX DEC BINARY HEX DEC BINARY HEX DEC BINARY HEX DEC BINARY HEX DEC
0000 0000 00 0 0010 0000 20 32 0100 0000 40 64 0110 0000 60 96 1000 0000 80 128 1010 0000 A0 160 1100 0000 C0 192 1110 0000 E0 224
0000 0001 01 1 0010 0001 21 33 0100 0001 41 65 0110 0001 61 97 1000 0001 81 129 1010 0001 A1 161 1100 0001 C1 193 1110 0001 E1 225
0000 0010 02 2 0010 0010 22 34 0100 0010 42 66 0110 0010 62 98 1000 0010 82 130 1010 0010 A2 162 1100 0010 C2 194 1110 0010 E2 226
0000 0011 03 3 0010 0011 23 35 0100 0011 43 67 0110 0011 63 99 1000 0011 83 131 1010 0011 A3 163 1100 0011 C3 195 1110 0011 E3 227
0000 0100 04 4 0010 0100 24 36 0100 0100 44 68 0110 0100 64 100 1000 0100 84 132 1010 0100 A4 164 1100 0100 C4 196 1110 0100 E4 228
0000 0101 05 5 0010 0101 25 37 0100 0101 45 69 0110 0101 65 101 1000 0101 85 133 1010 0101 A5 165 1100 0101 C5 197 1110 0101 E5 229
0000 0110 06 6 0010 0110 26 38 0100 0110 46 70 0110 0110 66 102 1000 0110 86 134 1010 0110 A6 166 1100 0110 C6 198 1110 0110 E6 230
0000 0111 07 7 0010 0111 27 39 0100 0111 47 71 0110 0111 67 103 1000 0111 87 135 1010 0111 A7 167 1100 0111 C7 199 1110 0111 E7 231
0000 1000 08 8 0010 1000 28 40 0100 1000 48 72 0110 1000 68 104 1000 1000 88 136 1010 1000 A8 168 1100 1000 C8 200 1110 1000 E8 232
0000 1001 09 9 0010 1001 29 41 0100 1001 49 73 0110 1001 69 105 1000 1001 89 137 1010 1001 A9 169 1100 1001 C9 201 1110 1001 E9 233
0000 1010 0A 10 0010 1010 2A 42 0100 1010 4A 74 0110 1010 6A 106 1000 1010 8A 138 1010 1010 AA 170 1100 1010 CA 202 1110 1010 EA 234
0000 1011 0B 11 0010 1011 2B 43 0100 1011 4B 75 0110 1011 6B 107 1000 1011 8B 139 1010 1011 AB 171 1100 1011 CB 203 1110 1011 EB 235
0000 1100 0C 12 0010 1100 2C 44 0100 1100 4C 76 0110 1100 6C 108 1000 1100 8C 140 1010 1100 AC 172 1100 1100 CC 204 1110 1100 EC 236
0000 1101 0D 13 0010 1101 2D 45 0100 1101 4D 77 0110 1101 6D 109 1000 1101 8D 141 1010 1101 AD 173 1100 1101 CD 205 1110 1101 ED 237
0000 1110 0E 14 0010 1110 2E 46 0100 1110 4E 78 0110 1110 6E 110 1000 1110 8E 142 1010 1110 AE 174 1100 1110 CE 206 1110 1110 EE 238
0000 1111 0F 15 0010 1111 2F 47 0100 1111 4F 79 0110 1111 6F 111 1000 1111 8F 143 1010 1111 AF 175 1100 1111 CF 207 1110 1111 EF 239
0001 0000 10 16 0011 0000 30 48 0101 0000 50 80 0111 0000 70 112 1001 0000 90 144 1011 0000 B0 176 1101 0000 D0 208 1111 0000 F0 240
0001 0001 11 17 0011 0001 31 49 0101 0001 51 81 0111 0001 71 113 1001 0001 91 145 1011 0001 B1 177 1101 0001 D1 209 1111 0001 F1 241
0001 0010 12 18 0011 0010 32 50 0101 0010 52 82 0111 0010 72 114 1001 0010 92 146 1011 0010 B2 178 1101 0010 D2 210 1111 0010 F2 242
0001 0011 13 19 0011 0011 33 51 0101 0011 53 83 0111 0011 73 115 1001 0011 93 147 1011 0011 B3 179 1101 0011 D3 211 1111 0011 F3 243
0001 0100 14 20 0011 0100 34 52 0101 0100 54 84 0111 0100 74 116 1001 0100 94 148 1011 0100 B4 180 1101 0100 D4 212 1111 0100 F4 244
0001 0101 15 21 0011 0101 35 53 0101 0101 55 85 0111 0101 75 117 1001 0101 95 149 1011 0101 B5 181 1101 0101 D5 213 1111 0101 F5 245
0001 0110 16 22 0011 0110 36 54 0101 0110 56 86 0111 0110 76 118 1001 0110 96 150 1011 0110 B6 182 1101 0110 D6 214 1111 0110 F6 246
0001 0111 17 23 0011 0111 37 55 0101 0111 57 87 0111 0111 77 119 1001 0111 97 151 1011 0111 B7 183 1101 0111 D7 215 1111 0111 F7 247
0001 1000 18 24 0011 1000 38 56 0101 1000 58 88 0111 1000 78 120 1001 1000 98 152 1011 1000 B8 184 1101 1000 D8 216 1111 1000 F8 248
0001 1001 19 25 0011 1001 39 57 0101 1001 59 89 0111 1001 79 121 1001 1001 99 153 1011 1001 B9 185 1101 1001 D9 217 1111 1001 F9 249
0001 1010 1A 26 0011 1010 3A 58 0101 1010 5A 90 0111 1010 7A 122 1001 1010 9A 154 1011 1010 BA 186 1101 1010 DA 218 1111 1010 FA 250
0001 1011 1B 27 0011 1011 3B 59 0101 1011 5B 91 0111 1011 7B 123 1001 1011 9B 155 1011 1011 BB 187 1101 1011 DB 219 1111 1011 FB 251
0001 1100 1C 28 0011 1100 3C 60 0101 1100 5C 92 0111 1100 7C 124 1001 1100 9C 156 1011 1100 BC 188 1101 1100 DC 220 1111 1100 FC 252
0001 1101 1D 29 0011 1101 3D 61 0101 1101 5D 93 0111 1101 7D 125 1001 1101 9D 157 1011 1101 BD 189 1101 1101 DD 221 1111 1101 FD 253
0001 1110 1E 30 0011 1110 3E 62 0101 1110 5E 94 0111 1110 7E 126 1001 1110 9E 158 1011 1110 BE 190 1101 1110 DE 222 1111 1110 FE 254
0001 1111 1F 31 0011 1111 3F 63 0101 1111 5F 95 0111 1111 7F 127 1001 1111 9F 159 1011 1111 BF 191 1101 1111 DF 223 1111 1111 FF 255
80
12 IQ Approvals
Refer to actuator nameplate for unit specific approval details
European – Hazardous area International – Hazardous area International Non hazardous

EExd IIB T4. ATEX (94/9/EC) II 2GD IECEx. Exd IIB T4 WT: Standard watertight, BS EN 60529 :1992,
Temperature -20°C to +70°C (-4°F to +158°F). IEC60079-0 and IEC60079-1 for Exd IIB T4 IP68, 7 metres/72 hours.
*Option -30°C to +70°C (-22°F to +158°F). Temperature -20°C to +60°C (-4°F to +140°F) Temperature -30°C to +70°C (-22°F to +158°F).
*Option -40°C to +70°C (-40°F to +158°F). *Option -30°C to +60°C (-22°F to +140°F). *Option -40°C to +70°C (-40°F to +158°F).
*Option -50°C to +40°C (- 58°F to +104°F). *Option -40°C to +60°C (-40°F to +140°F). *Option -50°C to +40°C (-58°F to +104°F).
*Option -50°C to +40°C (- 58°F to +104°F).
EExd IIC T4. ATEX (94/9/EC) II 2GD
Temperature -20°C to +70°C (-4°F to +158°F). IECEx. Exd IIC T4 US – Non hazardous
*Option -30°C to +70°C (-22°F to +158°F). IEC60079-0 and IEC60079-1 for Exd IIC T4 NEMA 4, 4X and 6.
*Option -40°C to +70°C (-40°F to +158°F). Temperature -20°C to +60°C (-4°F to +140°F). Temperature -30°C to +70°C (-22°F to +158°F).
*Option -50°C to +40°C (- 58°F to +104°F). *Option -40°C to +70°C (-40°F to +158°F).
*Option -50°C to +40°C (-58°F to +104°F).
EExde IIB T4. ATEX (94/9/EC) II 2GD USA – hazardous Area
Temperature -20°C to 70°C (-4°F to +158°F). FM. Class I, Division 1, Groups C & D, Class II,
*Option -30°C to +70°C (-22°F to +158°F). Division 1, Groups E, F & G. Canada – Non hazardous
*Option -40°C to +70°C (-40°F to +158°F). Factory Mutual - Explosionproof to NEC Article 500. CSA WT: Canadian Standard Association
*Option -50°C to +40°C (-58°F to +104°F). Temperature -30°C to +60°C (-22°F to +140°F). –Watertight.
EExde IIC T4. ATEX (94/9/EC) II 2GD *Option -40°C to +60°C (-40°F to +40°F). Wiring and components complying with CSA
Temperature -20°C to +70°C (-4°F to +158°F).
*Alternative for Group B hazardous area. Temperatures as for Enclosure 4 and 4X.
Groups C and D. Temperature -30°C to +70°C (-22°F to +158°F).
*Option -30°C to +70°C (-22°F to +158°F).
*Option -40°C to +70°C (-40°F to +158°F).
*Option -40°C to +70°C (-40°F to +158°F).
*Option -50°C to +40°C (-58°F to +104°F).
*Option -50°C to +40°C (- 58°F to +104°F). Canada – hazardous Area
CSA EP. Class I, Division 1, Groups C and D hazardous areas.
Canadian Standard Association - Explosionproof Rotork can supply actuators to national
Temperature -30°C to +70°C -22°F to +158°F). standards not listed above. For details please
*Option -50°C to +40°C (-58°F to +104°F). contact Rotork.
*Alternative for Group B hazardous area.
*Option -50°C to +40°C (- 58°F to +104°F).
Heading
Published and produced in the U.K. by Rotork Controls Ltd.

ATTENTION: RED PLASTIC PLUGS IN CONDUIT ENTRIES ARE FOR TRANSIT ONLY.
FOR LONG TERM PROTECTION FIT SUITABLE METAL PLUGS.

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

SON UNICAMENTE PARA TRANSPORTE. PARA PROTECCION PERMANENTE
COLOCAR TAPONES METALICOS APROPIADOS.
ACHTUNG: DIE ROTEN PLASTIKSTOPFEN SIND NUR FÜR DEN TRANSPORT

GEEIGNET. FÜR DAVERHAFTEN SCHUTZ SIND DIESE GEGEN GEEIGNETE
BLINDSTOPFEN AUSZÜTAUSCHEN.
ATTENTION: LES BOUCHONS PLASTIQUES ASSURENT UNE PROTECTION

TEMPORAIRE. POUR UNE PROTECTION DEFINITIVE UTILISER DES BOUCHONS
METALLIQUES.
As we are continually developing our products,

the design of Rotork actuators is subject to
change without notice. The latest product and
technical information is available at our
website: www.rotork.com.
The name Rotork is a registered trade mark.
Rotork recognises all registered trade marks.
MAL - STEAM DRAIN SYSTEM
servovalve SERVOVALVE ENGINEERING SRL
OPERATING INSTRUCTION HANDBOOK
for single acting actuator
series PAV
INDEX
1 GENERAL STANDARDS 3 TECHNICAL SHEET
1.1 INTRODUCTION Page 2 3.1 OPERATING WITH MANUAL DEVICE Page 5
1.2 ACTUATOR WARRANTY STANDARDS Page 2 3.2 VALVE COUPLING Page 5
1.3 PACKING STANDARDS Page 2 3.3 STOP SCREW SETTING Page 5
1.4 STORAGE STANDARDS Page 2 3.4 ACTUATOR DISASSEMBLING Page 5
1.5 HANDLING STANDARDS Page 3 3.5 EQUIPMENTS AND ACTUATOR SPARE PART LIST Page 5
1.6 DELIVERY STANDARDS Page 3 3.6 ACTUATOR ASSEMBLING Page 5
1.7 ASSEMBLING STANDARDS Page 3 3.7 LUBRICATION Page 5
1.8 STARTING UP STANDARDS Page 3 3.8 MEDIUM SUPPLY CHARACTERISTICS Page 5
1.9 WARNINGS Page 3 3.9 TROUBLESHOOTING Page 6
2 GENERAL DESCRIPTION ENCLOSED DRAWINGS:

2.1 WORKING Page 4 - PAV 125 – 200 DWG. SA006 Rev2
2.2 EMERGENCY MANUAL DEVICE Page 4 - PAV 250 – 300 DWG. SA007 Rev3
2.3 COUPLING TO THE VALVE Page 4 - PAV C.L. 250 – 300 DWG. SA008 Rev3
2.4 MAINTENANCE Page 4 - PAV C.L. 360 – 420 DWG. SA036 Rev3
2.5 SPARE PARTS Page 4
2.6 RECOMMENDED CHECKS Page 4 TECHNICAL PERFORMANCES, DIMENSIONS, COUPLINGS
SEE OUR CATALOGUE
SERVOVALVE has taken any care in collecting and verifying the documentation contained in this handbook, that may be
modified without any notice.
SERVOVALVE refuses any liability for damages to people and/or goods caused by misuse of the actuator or by the lack
of respect of the current safety standards.
Nevertheless SERVOVALVE will not be responsible for any mistake contained in it or for every damage, either accidental
or not, due to the use of this handbook.
SERVOVALVE engineering srl Handbook L30 (PAV) Page 1 of 6

1 General standards
1.1 Introduction
This manual gives instructions for standard packing, carriage, Original spare parts
handling, storage, assembling, disassembling, starting-up and In case of use of non-original spare parts by the customer,
maintenance of the actuator in object. SERVOVALVE declines all responsibilities for indemnity on
claims.
For different conditions SERVOVALVE must be inform before
order and supply. Operative staff
The lack of knowledge of the operative staff about the
operating instruction handbook supplied by SERVOVALVE
1.2 Actuator warranty in the language specified in the order, cannot be ascribed to
SERVOVALVE.
SERVOVALVE warrants that the actuator is in compliance with
the documents and the specifications indicated in the Customer Working interruptions and down time
purchase order. Damages due to a prolonged working interruption and/or
down time, during which the actuator was not in such
Moreover, SERVOVALVE warrants that materials and conditions to assure a perfect preservation, will be the
equipment supplied together with the actuator are new and that customer’s account.
the product developed by SERVOVALVE is suitable to its final
scopes and purposes. Actuator modifications
Any actuator modification has to be carried out in
The warranty standards follow the below indicated conditions: SERVOVALVE workshop.
Any damage due to any modification carried out by the
Terms customer or by third parties, will be on the customer’s
Every SERVOVALVE product is warranted for a defined term account.
starting from delivery date from our workshop.
As an exception of particular written agreements between the Tampering
two parts, our products are warranted for a maximum working Warranty declines in case the actuator is tampered by third-
period of 12 months and, in any case, for a period not superior parties without SERVOVALVE authorisation.
of 18 months starting from the delivery date from our workshop,
with the only exclusion of the wearing components. Here below, general standards regarding actuator packing,
handling, carriage, storage, assembling and disassembling,
Environmental working conditions start-up, maintenance and repair are reported.
The warranty is valid for environmental conditions specified
onto the data-plate and maximum humidity 60%. WARNING: the lack of respect of the above mentioned
Particular conditions as high salinity, presence of corrosive standards will invalid SERVOVALVE
elements, high humidity, tropical or arctic temperatures, seismic warranty.
risks, high vibrations must be specified by the Customer when
he places his purchase order.
1.3 Packing
Installation/working conditions
Particularly troubled installation and particularly severe duty Before delivery, every actuator is packed onto pallets,
have to be specified during order issue in order to take into cages or cases, in order to prevent it from deterioration
account the necessary technical measures. during shipping and storage.
Damages due to corrosion, fouling, pollution, oxidation, dust, Except for specific requests during order issue, standard
wear or progressive deterioration, caused by environmental SERVOVALVE packages are suitable for transport on
working conditions or caused by severe duty and installation vehicles with chest protected from atmospheric agents.
conditions for which the customer did not specify the
adaptability limits, will be on the customer’s account.
Equipment guarantee 1.4 Storage

Guarantee conditions of an equipment installed onto a
SERVOVALVE actuator refer to the ones established by the Brief time storage (less than three months from the shipping
equipment supplier. ex our workshop)
Be sure that actuators are stored in a closed and dry place,
Repairs/replacements and guarantee extension onto pallets and protected from dust and humidity.
If any part has to be repaired/replaced because of bad
functionality or damage due to SERVOVALVE manufacture, the Long time storage
replacement/repair has to be carried out ex our workshop. Actuators have to be stored in cases or cages with suitable
The guarantee extension will be equal to 12 months starting waterproof coating.
from the repair/replacement date and it will cover only the
repaired/replaced part. Outdoor storage of the actuator is not foreseen, unless
it is specified in the purchase order.

1.5 Handling 1.8 Starting up
Handling has to be carried out by means of fixed and moving
devices that are suitable for the actuator weight. Before the actuator starts operating, check its correct
Besides, handling has to be carried out by qualified personnel. functionality.
- Actuators whose weight is more than 25 kg are provided - Check if the electrical connections are correct, check if
with eye bolts, hooks or lifting points for the handling the voltage supply is correct ( as required by the supplied
when are used cranes or other mechanical lifting systems. equipment ) and check if the actuator is grounded through
- Lifting points are sized for handling only the actuator. the specific given point.
- It is forbidden to use the actuator lifting devices in order to - Check if the pneumatic connections and the medium
handle the assembly valve + actuator or to handle other supply pressure are correct.
equipment linked to it. - Check if the hydraulic connections and the medium
- Handling has to be carried out with care by qualified supply pressure are correct.
personnel without causing any damage to the packing in - Check if the safety devices for pressure parts, where
order to guarantee an adequate protection of the product. foreseen, are working properly.
- Handling has to be carried out in such conditions to avoid - Check if the coupling actuator-valve is correct.
damage the equipment inside the package, respecting the
indications on the package surface. Operation
- During handling take care not to damage unmachined - Check if the actuator movement is regular.
surfaces and not to damage the paint. - Check if the mechanical moving parts are lubricated ( if it
is required ).
Take always care, when handling, that the actuator does not fall
down and does not cause damages if it is handled over staff Test
areas or other workshop areas It is necessary to make few testing manoeuvres checking
Always respect the safety standards in force. that:
- Before making every handling operation it is necessary - Parts under pressure do not have leakage.
that: - Mechanical parts are able to move without hunting or
- Qualified personnel must know the technical characteristic tears.
of the lifting device used. - The drive and regulating equipment work in a correct way
- Personnel must not have body or part of it under the lifted
load. 1.9 Common warnings
- Before making any lifting, prepare the support surface.
- Do not use the lifting devices at their maximum range or Environmental temperature in which the actuator is placed
above it. must not exceed the allowable limits given on the data-
- Check the integrity and functionality of the lifting device. plate.
1.6 Delivery - Do not exceed actuator’s fluid maximum allowable

pressure given on the data-plate.
In order not do damage the actuator during delivery, proceed as - Do not exceed actuator’s maximum allowable
follows: temperature given on the data-plate.
- Put the packages in position that could not be moved or - Actuator must be joined to the valve to be actuated only
knocked by chance. by means of the suitable coupling devices. These
- Avoid any contact with chemically aggressive fluids or devices shall protect the actuator from exceeding the
solids. max. allowable temperature given on the data plate
- The external surfaces not machined are painted; take Eventual additional links/joints are forbidden.
extreme care not to damage it during carriage. - It is forbidden to unscrew nut bolts of the pressure
- Do not put the packing one upon another if not indicated. vessel in every situation but in maintenance, where the
- Respect the indications written on the package ( fragile, operating instruction handbook has to be followed
high, low … ). carefully.
- Packing movement has to be made by qualified personnel - It is forbidden to perform welding or modifications onto
following the security standard in force. the pressure vessel.
- Actuator is not suitable for installations in environmental
conditions different to those specified in the purchase
order.
1.7 Assembling - It is forbidden to handle the assembly valve+actuator
with the actuator lifting devices.
Only qualified personnel can couple the actuator to the valve. - Before start-up, check if any part of the actuator has
When coupling, follow the security standard in force for this kind
been damaged.
of operation both for personnel and machinery.
- Before start-up, check if the actuator has been
In detail, follow every particular prescription indicated in this grounded through the specific given point.
instruction handbook.
- Actuator is designed to resist to no stresses but to
Actuator coupling to the valve is not under SERVOVALVE
those foreseen for actuating the valve to which it is
responsibility and, therefore it is not covered by SERVOVALVE coupled.
warranty.
- Avoid working condition with vibrations with too high
intensity and amplitude.
Anyway, respect the following prescriptions:
- Perform maintenance foreseen by the manufacturer.
- Before assembling, check the actuator preservation state - For every other restriction/caution, refer to the operating
because corrosion , eventual knocks or events that reduce instruction handbook.
the safety or the functionality performance during packing,
carriage and storage of the product, could happen.
- Qualified personnel must assemble the mechanical,

pneumatic, hydraulic and electrical parts in a state of the art
way.
- Respect every safety standard in force when connecting to
energy sources ( electrical, pneumatic, hydraulic… ).

2 General description
The linear actuator type PA has been designed to operate gate WARNING: before disassembling the actuator from the
or globe valve. valve, maintenance personnel must assure
The PA actuator consist of a pneumatic single acting actuator itself that the valve is depressurised and that
with return spring. every connection to energy feeds is cut-off.
It is operated by means of a medium like air or gas.
Putting air inside the cylinder, the piston goes down, closing For safety reasons, maintenance personnel must always
the valve and compressing the spring. wear during maintenance:
When the medium fails the spring pushes up the piston opening - protective glasses (face shields)
the valve. - gloves, overalls, hard hats and protective boots
The actuator can be equipped with pneumatic or electric
equipments (solenoid valve, positioner, transmitter, filter, air 2.4.2 Maintenance general standards
reductor, lubricator, limit switch, ect).
If requested, the actuator can be equipped with a manual No particular maintenance is required for the actuator.
emergency device to allow the actuator moving in case of fail of Periodical inspections can be done during the working life,
the medium supply. the inspection frequency is due to environmental and duty
The manual device can be a handwheel (PAV) or a manual conditions in the plant.
gear (PAR).
2.4.3 Maintenance operative instructions
2.1 Working
Dynamic seals and mechanical parts in movement have an
Every time the medium is blown inside the cylinder, the piston average life of years in standard working conditions.
push down the actuator shaft closing the valve and, at the same
time, providing to the spring compression. For these parts it is advised a yearly check and it is advised
Every time the medium pressure fails, the spring, elongating to foresee an eventual replacement of the seals after two
itself, pushes up the piston pulling the valve shaft in open working years.
position.
The PA actuator can operate a modulating or on-off valve. Parts not subjected to wear are sized for a long working
The medium supply must respect the technical requirements time even in heavy or severe duty conditions.
listed ahead in part 3 of this handbook.
2.2 Emergency manual device 2.5 Spare parts

2.5 .1 Introduction
PAV are equipped with a handwheel.
The suggested spare parts for two years are pointed out to
part 3.5.
How to operate with manual emergency device see description
pos. 3.1 To order actuator spare parts or equipment supplied by
SERVOVALVE, specify the actuator serial number indicated
onto the actuator data-plate.
2.3 Coupling to the valve Only if the actuator serial number is not available for any
reason, the customer has to specify as most information as
For coupling see description pos. 3.2
possible, like:
1. SERVOVALVE’s purchaser name

2.4 Maintenance 2. Purchaser Order number
3. Reference to a SERVOVALVE drawing
2.4.1 Operating restrictions 4. SERVOVALVE job number
Maintenance operations must be carried out by qualified 2.5.2 Actuator and equipment part list
personnel. This personnel must be perfectly acknowledged
about operative techniques and about safety standards in All the actuator parts are listed in the actuator section
force, the respect of whose is necessary for its safety and the drawing part list, and all the equipment are showed in the
safety of other people. circuit drawing part list.
Suggested spare parts for the commissioning and/or two
working years, if they are required, are showed ahead in
part 3. of this handbook.
2.6 Recommended checks

Checks Possible damages Remedies
Check that the actuator is rigidly fixed to the valve Loosening of the coupling nuts Lock all the coupling nuts
If installed in aggressive environment check the Seals damaged Repair the corrosion onto the shaft and
cylinder shaft has not corrosion replace all the cylinder shaft seals
Check that there are no signs of corrosion on the Possible bad working or damages Repair the corrosion signs and re-paint
actuator the actuator
Check that there are no medium leakage Leakage between flanges and cylinder Replace static seals
Check there are not a continuous medium leakage Leakage from piston seals Replace piston seals
from the exhaust hole of the cylinder

3. Technical sheet
3.1 Operating with manual device B) Only for PAV C.L. with diameter from 250 to 300 and
PAV C.L. with diameter from 360 to 420
PAV actuators are equipped with handwheel for manual 1. Unscrew the nut (911) and take away the manual
emergency operations when power fluid fails. device.
For manual emergency operation, when the medium supply 2. Take away the stay bolts (312) and the tube (321).
fails, proceed the following way: 3. Unscrew with care the safety bolt (326), take away the
spring disc (328) and the spring (306).
1. For opening the valve, turn the handwheel in 4. Unscrew the dowel (918), the tube sleeve (355) and the
counterclockwise direction. screws (910).
2. For closing the valve, turn the handwheel in clockwise 5. Unscrew the nut (909) and withdraw the flange (342),
direction. the superior head (314), the stay bolys (319) and the
tube (304).
WARNING: when emergency is over, before moving the 6. Unscrew the dowel (904), the superior shaft (343) and
actuator with the actuation medium, the the ring nut (308).
handwheel must be positioned in stand-by 7. Withdraw the piston (305) and the shaft (303) from the
position (open completely the valve with the inferior head (301).
handwheel and leave it in open position).
3.5 Equipment and actuator spare part list
3.2 Valve coupling
The actuator is coupled to the valve flange by means of a joke SERVOVALVE suggests the following spare parts for
with a terminal flange or columns. commissioning and/or for two working years (positions see the
The valve stem is yoked to the actuator shaft by a rigid sleeve enclosed section dwg):
or muff.
The upper chamber of the cylinder is connected by means of For all actuators
fittings to the compressed air piping of the pneumatic circuit.ù Pos. 801 O-ring n° 2
Pos. 811 Gasket n° 1
1. If the actuator is equipped with columns, fit directly the Pos. 812 O-ring n° 1
screw columns inside the valve flange holes and lock with
nuts. If the actuator is equipped with a flanged joke, lock it Only for PAV with diameter from 125 to 200
to the valve flange by means of screws and nuts. Pos. 808 Piston n° 1
2. Connect with a hub the shaft of the valve with the shaft of
the actuator. Only for PAV with diameter from 250 to 300
Pos. 802 O-ring n° 2
3.3 Stop screw setting Pos. 809 Slide n° 1
Generally the actuator stroke is stopped by the valve stroke and

Only for PAV C.L. with diameter from 250 to 300 and
no stroke settings are required.
PAV C.L. with diameter from 360 to 420
If the actuator stroke has to be stopped, the actuator itself has
to be supplied with stop screws only if requested in the
purchase order.
Pos. 809 Slide n° 1
3.4 Actuator disassembling
WARNING: before disassembling the actuator, its must be 3.6 Actuator assembling
uncoupled from the valve
In order to carry out the actuator assembling, perform the
WARNING: before removing the actuator from the valve, operations described at point 3.4 following the opposite
qualified personnel must assure itself that the operations sequence, after having replaced all the seals.
actuator is depressurised and every energy
connections are cut-off. SERVOVALVE suggest to replace new gaskets every time the
actuator has been disassembled and assembled.
After having uncoupled the actuator from the valve and having
unconnected and dismounted all the respective equipment,
proceed as follows (positions see enclosed section dwg): 3.7 Lubrication
WARNING: the actuator contains a pre-loaded spring, An adequate lubrication is essential to maintain the actuator
therefore unload the spring very carefully, in optimal condition throughout all its intended life.
unscrewing uniformly the safety bolts.
The actuator is supplied with a lifetime lubrication an added
A) Only for PAV with diameter from 125 to 200 and PAV lubrication is not required; if the actuator is disassembled
with diameter from 250 to 300 before assembled the mechanical parts in motion need a
1. Unscrew the eye bolt (912) the screw (908) and take new lubrication.
away the handwheel (349).
2. Unscrew the nut (919), take away the screw thread Suggested lubricants:
(347) the stay bolt (346) and the tube (345).
3. Unscrew the dowel (921) and the ring nut (344). Shell ALVANIA 3EP
4. Unscrew the stay bolt (312), withdraw the flange (342), Agip GREASE MU 3EP
the superior head (341) and the cylinder (304). Esso BEACOM 3EP
5. Take away the dowels (904), unscrew the superior shaft
(343) and the ring nut (308).
6. Witdraw the piston (305 or 808) the spring (306) and
3.8 Medium supply characteristics
the shaft (303) from the inferior head (301).
It is recommended to use filtered and no-oiled mediums.
If the medium to be used is air, instrument air is
recommended.

3.9 Troubleshooting
Description Trouble Remedy
Actuator blocked Damaged coupling between valve and Verify coupling and actuator moving
actuator or shaft seizure
1. no medium supply 1. verify the supply circuit

Actuator does not move
2. troubleshoot of the working 2. verify pneumatic equipment
pneumatic equipment
3. no electric energy to the electric 3. verify electric circuit

equipment
Actuator has great leakage from the Seals damaged Disassemble actuator and replace all
head the seals

servovalve
SERVOVALVE spa
Via Quasimodo 25/27 S.Stefano Ticino (MI)
PHONE: 0039 - 02 - 974846.1
FAX: 0039 - 02 - 974846.46
Email: servovalve@servovalve.it
OPERATING INSTRUCTION HANDBOOK
for single acting actuator
series RPM
(execution for check valve)
INDEX
1 GENERAL STANDARDS 3 TECHNICAL SHEET
1.1 INTRODUCTION Page 2 3.1 VALVE COUPLING Page 5
1.2 ACTUATOR WARRANTY STANDARDS Page 2 3.2 STOP SCREW SETTING Page 5
1.3 PACKING STANDARDS Page 2 3.3 ACTUATOR DISASSEMBLING Page 5
1.4 STORAGE STANDARDS Page 2 3.4 EQUIPMENTS AND SPARE PART LIST Page 5
1.5 HANDLING STANDARDS Page 3 3.5 ACTUATOR ASSEMBLING Page 5
1.6 DELIVERY STANDARDS Page 3 3.6 LUBRICATION Page 5
1.7 ASSEMBLING STANDARDS Page 3 3.7 MEDIUM SUPPLY CHARACTERISTICS Page 5
1.8 STARTING UP STANDARDS Page 3 3.8 TROUBLESHOOTING Page 5
1.9 WARNINGS Page 3
2 GENERAL DESCRIPTION ENCLOSED DRAWINGS:

2.1 WORKING Page 4 - RPM DWG. D-3355 Rev 6
2.2 COUPLING TO THE VALVE Page 4 - RPM DWG. D-3382 Rev 3
2.3 MAINTENANCE Page 4
2.4 SPARE PARTS Page 4 TECHNICAL PERFORMANCES, DIMENSIONS, COUPLINGS
2.5 RECOMMENDED CHECKS Page 4 SEE OUR CATALOGUE
SERVOVALVE has taken any care in collecting and verifying the documentation contained in this handbook, that may be
modified without any notice.
SERVOVALVE refuses any liability for damages to people and/or goods caused by misuse of the actuator or by the lack of
respect of the current safety standards.
Nevertheless SERVOVALVE will not be responsible for any mistake contained in it or for every damage, either accidental
or not, due to the use of this handbook.
SERVOVALVE Handbook PR10-EN (RPM) Page 1 of 5

1 General standards
1.1 Introduction
This manual gives instructions for standard packing, carriage, Original spare parts
handling, storage, assembling, disassembling, starting-up and In case of use of non-original spare parts by the customer,
maintenance of the actuator in object. SERVOVALVE declines all responsibilities for indemnity on
claims.
For different conditions SERVOVALVE must be inform before
order and supply. Operative staff
The lack of knowledge of the operative staff about the
operating instruction handbook supplied by SERVOVALVE
1.2 Actuator warranty in the language specified in the order, cannot be ascribed to
SERVOVALVE.
SERVOVALVE warrants that the actuator is in compliance with
the documents and the specifications indicated in the Customer Working interruptions and down time
purchase order. Damages due to a prolonged working interruption and/or
down time, during which the actuator was not in such
Moreover, SERVOVALVE warrants that materials and conditions to assure a perfect preservation, will be the
equipment supplied together with the actuator are new and that customer’s account.
the product developed by SERVOVALVE is suitable to its final
scopes and purposes. Actuator modifications
Any actuator modification has to be carried out in
The warranty standards follow the below indicated conditions: SERVOVALVE workshop.
Any damage due to any modification carried out by the
Terms customer or by third parties, will be on the customer’s
Every SERVOVALVE product is warranted for a defined term account.
starting from delivery date from our workshop.
As an exception of particular written agreements between the Tampering
two parts, our products are warranted for a maximum working Warranty declines in case the actuator is tampered by third-
period of 12 months and, in any case, for a period not superior parties without SERVOVALVE authorization.
of 18 months starting from the delivery date from our workshop,
with the only exclusion of the wearing components. Here below, general standards regarding actuator packing,
handling, carriage, storage, assembling and disassembling,
Environmental working conditions start-up, maintenance and repair are reported.
The warranty is valid for environmental conditions specified
onto the data-plate and maximum humidity 60%. WARNING: the lack of respect of the above mentioned
Particular conditions as high salinity, presence of corrosive standards will invalid SERVOVALVE
elements, high humidity, tropical or arctic temperatures, seismic warranty.
risks, high vibrations must be specified by the Customer when
he places his purchase order.
1.3 Packing
Installation/working conditions
Particularly troubled installation and particularly severe duty Before delivery, every actuator is packed onto pallets,
have to be specified during order issue in order to take into cages or cases, in order to prevent it from deterioration
account the necessary technical measures. during shipping and storage.
Damages due to corrosion, fouling, pollution, oxidation, dust, Except for specific requests during order issue, standard
wear or progressive deterioration, caused by environmental SERVOVALVE packages are suitable for transport on
working conditions or caused by severe duty and installation vehicles with chest protected from atmospheric agents.
conditions for which the customer did not specify the
adaptability limits, will be on the customer’s account.
Equipment guarantee 1.4 Storage

Guarantee conditions of an equipment installed onto a
SERVOVALVE actuator refer to the ones established by the Brief time storage (less than three months from the shipping
equipment supplier. ex our workshop)
Be sure that actuators are stored in a closed and dry place,
Repairs/replacements and guarantee extension onto pallets and protected from dust and humidity.
If any part has to be repaired/replaced because of bad
functionality or damage due to SERVOVALVE manufacture, the Long time storage
replacement/repair has to be carried out ex our workshop. Actuators have to be stored in cases or cages with suitable
The guarantee extension will be equal to 12 months starting waterproof coating.
from the repair/replacement date and it will cover only the
repaired/replaced part. Outdoor storage of the actuator is not foreseen, unless
it is specified in the purchase order.

1.5 Handling 1.8 Starting up
Handling has to be carried out by means of fixed and moving
devices that are suitable for the actuator weight. Before the actuator starts operating, check its correct
Besides, handling has to be carried out by qualified personnel. functionality.
- Actuators whose weight is more than 25 kg are provided - Check if the electrical connections are correct, check if
with eye bolts, hooks or lifting points for the handling the voltage supply is correct ( as required by the supplied
when are used cranes or other mechanical lifting systems. equipment ) and check if the actuator is grounded through
- Lifting points are sized for handling only the actuator. the specific given point.
- It is forbidden to use the actuator lifting devices in order to - Check if the pneumatic connections and the medium
handle the assembly valve + actuator or to handle other supply pressure are correct.
equipment linked to it. - Check if the hydraulic connections and the medium
- Handling has to be carried out with care by qualified supply pressure are correct.
personnel without causing any damage to the packing in - Check if the safety devices for pressure parts, where
order to guarantee an adequate protection of the product. foreseen, are working properly.
- Handling has to be carried out in such conditions to avoid - Check if the coupling actuator-valve is correct.
damage the equipment inside the package, respecting the
indications on the package surface. Operation
- During handling take care not to damage unmachined - Check if the actuator movement is regular.
surfaces and not to damage the paint. - Check if the mechanical moving parts are lubricated ( if it
is required ).
Take always care, when handling, that the actuator does not fall
down and does not cause damages if it is handled over staff Test
areas or other workshop areas It is necessary to make few testing maneuvers checking
Always respect the safety standards in force. that:
- Before making every handling operation it is necessary - Parts under pressure do not have leakage.
that: - Mechanical parts are able to move without hunting or
- Qualified personnel must know the technical characteristic tears.
of the lifting device used. - The drive and regulating equipment work in a correct way
- Personnel must not have body or part of it under the lifted
load. 1.9 Common warnings
- Before making any lifting, prepare the support surface.
- Do not use the lifting devices at their maximum range or Environmental temperature in which the actuator is placed
above it. must not exceed the allowable limits given on the data-
- Check the integrity and functionality of the lifting device. plate.
1.6 Delivery - Do not exceed actuator’s fluid maximum allowable

pressure given on the data-plate.
In order not do damage the actuator during delivery, proceed as - Do not exceed actuator’s maximum allowable
follows: temperature given on the data-plate.
- Put the packages in position that could not be moved or - Actuator must be joined to the valve to be actuated only
knocked by chance. by means of the suitable coupling devices. These
- Avoid any contact with chemically aggressive fluids or devices shall protect the actuator from exceeding the
solids. max. allowable temperature given on the data plate
- The external surfaces not machined are painted; take Eventual additional links/joints are forbidden.
extreme care not to damage it during carriage. - It is forbidden to unscrew nut bolts of the pressure
- Do not put the packing one upon another if not indicated. vessel in every situation but in maintenance, where the
- Respect the indications written on the package ( fragile, operating instruction handbook has to be followed
high, low … ). carefully.
- Packing movement has to be made by qualified personnel - It is forbidden to perform welding or modifications onto
following the security standard in force. the pressure vessel.
- Actuator is not suitable for installations in environmental
conditions different to those specified in the purchase
order.
1.7 Assembling - It is forbidden to handle the assembly valve+actuator
with the actuator lifting devices.
Only qualified personnel can couple the actuator to the valve.
- Before start-up, check if any part of the actuator has
When coupling, follow the security standard in force for this kind been damaged.
of operation both for personnel and machinery.
- Before start-up, check if the actuator has been
In detail, follow every particular prescription indicated in this
grounded through the specific given point.
instruction handbook. - Actuator is designed to resist to no stresses but to
Actuator coupling to the valve is not under SERVOVALVE
those foreseen for actuating the valve to which it is
responsibility and, therefore it is not covered by SERVOVALVE
coupled.
warranty. - Avoid working condition with vibrations with too high
intensity and amplitude.
Anyway, respect the following prescriptions:
- Perform maintenance foreseen by the manufacturer.
- Before assembling, check the actuator preservation state - For every other restriction/caution, refer to the operating
because corrosion , eventual knocks or events that reduce instruction handbook.
the safety or the functionality performance during packing,
carriage and storage of the product, could happen.
- Qualified personnel must assemble the mechanical,

pneumatic, hydraulic and electrical parts in a state of the art
way.
- Respect every safety standard in force when connecting to
energy sources ( electrical, pneumatic, hydraulic… ).

2 General description
The RPM actuators have been created for the transmission of 2.3.2 Maintenance general standards
high torque for quarter-turn rotations of the out-going shaft.
The actuator is suitable to operate valves with a working No particular maintenance is required for the actuator.
angular stroke not large than 90° (+/-6°). Periodical inspections can be done during the working life,
In a central housing, located between two pneumatic cylinder the inspection frequency is due to environmental and duty
with a spring return, a rack and pinion kinematism converts conditions in the plant.
the linear cylinder movement in to a 90° rotation torque.
The power fluid can be pressured instrument air. 2.3.3 Maintenance operative instructions
The actuator is coupled to a non-return valve and allows to
force the closing rotation of the clapet of the valve in case of Dynamic seals and mechanical parts in movement have an
quick emergency shut-down. average life of years in standard working conditions.
2.1 Working For these parts it is advised a yearly check and it is advised
to foresee an eventual replacement of the seals after two
The pressured air, reaches the pneumatic cylinder of the working years.
actuator, pushing the piston and compressing the spring.
The rack and pinion, turns the shaft of the actuator, making free Parts not subjected to wear are sized for a long working
the clapet of the non-return valve. time even in heavy or severe duty conditions.
In this case the clapet of the valve is free to swing.
In emergency the pressured air discharges and spring turns
quickly back the pinion of the actuator pushing the clapet in 2.4 Spare parts
closing position.
The action of the actuator in closing the valve is only for the first 2.4 .1 Introduction
part of the closing stroke.
The actuator is not designed to keep the valve closed The suggested spare parts for two years are pointed out to
against the full opening pressure of the fluid on the valve. part 3.4.
2.2 Coupling to the valve To order actuator spare parts or equipment supplied by
SERVOVALVE, specify the actuator serial number indicated
For coupling see description pos. 3.1 onto the actuator data-plate.
Only if the actuator serial number is not available for any

reason, the customer has to specify as most information as
2.3 Maintenance possible, like:
2.3.1 Operating restrictions
1. SERVOVALVE’s purchaser name
2. Purchaser Order number
Maintenance operations must be carried out by qualified
3. Reference to a SERVOVALVE drawing
Personnel. This personnel must be perfectly acknowledged
4. SERVOVALVE job number
About operative techniques and about safety standards in
force, the respect of whose is necessary for its safety and
2.4.2 Actuator and equipment part list
the safety of other people.
All the actuator parts are listed in the actuator section
WARNING: before disassembling the actuator from the
drawing part list.
valve, maintenance personnel must assure
Suggested spare parts for the commissioning and/or two
itself that the valve is depressurized and that
working years, if they are required, are showed ahead in
every connection to energy feeds is cut-off.
part 3. of this handbook.
For safety reasons, maintenance personnel must always
wear during maintenance:
- protective glasses (face shields)
- gloves, overalls, hard hats and protective boots
2.5 Recommended checks

Checks Possible damages Remedies
Check that the actuator is rigidly fixed to the valve Loosening of the coupling nuts Lock all the coupling nuts
If installed in aggressive environment check the Seals damaged Repair the corrosion onto the shaft and
cylinder shaft has not corrosion replace all the cylinder shaft seals
Check that there are no signs of corrosion on the Possible bad working or damages Repair the corrosion signs and re-paint
actuator the actuator
Check that there are no medium leakage Leakage between flanges and cylinder Replace static seals
Check there are not a continuous medium leakage Leakage from piston seals Replace piston seals
from the exhaust chamber of the cylinder

3. Technical sheet
3.3.3) Housing disassembling
3.1 Valve coupling
Take out the lock ring (21) and extract the pinion (2) from the
For coupling the actuator to the valve, proceed as follow (all the
inferior side of the housing and withdraw the shaft (3).
displayed positions that follow in this part refer to the enclosed
section dwg):
3.4 Equipment and actuator spare part list
1) Take away the caps (7) and completely unscrew the
mechanical stop screws (9) piston side.
SERVOVALVE suggests the following spare parts for
2) Set the valve in the corresponding fail position.
commissioning and/or for two working years (positions see the
3) Insert the keys into the valve shaft and fit the valve shaft enclosed section dwg):
into the wheel hole.
4) Adjust the actuator alignment in respect to the valve
Pos. 4 piston n° 2
coupling flange using the medium pressure. Pos. 8 washer n° 1
5) Fix the coupling with the block screws.
Pos. 16 O-Ring gasket n° 1
3.2 Stop screw setting Pos. 18 O-Ring gasket n° 1
Coupling valve and actuator flanges, set the stop screws in the
following way:
3.5 Actuator assembling
1) Set the actuator in the fail position. If necessary, adjust
the exact fail position using the medium pressure. In order to carry out the actuator assembling, perform the
2) Screw the stop-screw (9) piston side until it reaches the operations described at point 3.3 following the opposite
piston and block it with nut (7). operations sequence, after having replaced all the seals.
3) using the actuation fluid pressure, set the actuator in the
opposite final position. SERVOVALVE suggest to replace new gaskets every time
4) Screw the other stop-screw (57) spring side until it the actuator has been disassembled and assembled.
reaches the disc (52) and block it with nut (7).
3.6 Lubrication
3.3 Actuator disassembling
WARNING: before removing the actuator from the valve, An adequate lubrication is essential to maintain the actuator
qualified personnel must assure itself that the in optimal condition throughout all its intended life.
valve is depressurized and every energy
connections are cut-off. The actuator is supplied with a lifetime lubrication an added
lubrication is not required; if the actuator is disassembled
After having uncoupled the actuator from the valve and having before assembled the mechanical parts in motion need a
unconnected and dismounted all the eventual equipment, new lubrication.
proceed as follows (positions see enclosed section dwg): Suggested lubricants:
Shell ALVANIA 3EP

WARNING: the actuator contains a pre-loaded spring, Agip GREASE MU 3EP
therefore unload the spring very carefully, Esso BEACOM 3EP
unscrewing uniformly the safety bolts.
3.7 Medium supply characteristics
3.3.1) Spring cartridge disassembling
It is recommended to use filtered and no-oiled mediums.
unscrew the nuts (14) uniformly and take away the related If the medium to be used is air, instrument air is
safety bolts , take out the outer flange (54), the cartridge (51) recommended.
and the spring (53)
unscrew the disc (52) and withdraw the piston (4)
3.3.2) Cylinder disassembling
unscrew the nuts (14) and take out the outer flange (5) and
withdraw the stay bolts and take out the cylinder (6).
Unscrew the nut (10) and withdraw the piston (4)
3.8 Troubleshooting
Description Trouble Remedy
Actuator blocked Damaged coupling between valve and Verify coupling and actuator moving
actuator or shaft seizure
Actuator does not move 1. no medium supply 1. verify the supply circuit
2. troubleshoot of the working 2. verify pneumatic equipment

pneumatic equipment
3. no electric energy to the electric 3. verify electric circuit

equipment
Actuator has great leakage from the Seals damaged Disassemble actuator and replace all
exhaust chamber the seals

YAN CHENG VIZA VALVE MANUFACTURING CO.,LTD Doc. VI-1001 ENG
Installation and Maintenance Instructions (start-up manual)

Bolted Bonnet Gate Valves
Basic Configuration-Flanged or Welded Ends
Valve Storage
1.1 Preparation and Preservation for Shipment
All valves are properly packed in order to protect the parts that are subject to deterioration during
transportation and storage on site. In particular, the following precautions should be taken:
1. The valves must be packed with the wedge in the closed position.
1a. Flanged end valves: The flange sealing surfaces (raised faces) of the valves shall be
protected with suitable protective grease. The end faces of the valve must be protected with
plastic or wooden discs fixed with straps.
1b. Butt weld end valves: The weld ends surface shall be protected with suitable protective. The
end shall be closed with plywood or plastic disc fixed at the edge by straps.
2. All actuated valves must be carefully and securely palleted or crated, in order to ensure that the
parts of actuator (especially pneumatic piping or accessories) do not extend beyond the
skid/crate.
3. The type of packing must be defined in the Customer’s Order and shall be appropriate to
ensure safe transportation to final destination and eventual conservation before installation.
1.2 Handling Requirements

A - Packed Valves
Crates: Lifting and handling of the packed valves in crates will be carried out by a forklift truck, by
means of the appropriate fork hitches.
Cases: The lifting of packed valves in cases should be carried out in the lifting points and at the
center of gravity position, which have been marked. The transportation of all packed material must
be carried out safely and following the local safety regulations.
B - Unpacked Valves
1. The lifting and the handling of these valves has to be carried out by using appropriate means
and by respecting the carrying limits. The handling must be carried out on pallets, protecting the
machined surfaces to avoid any damage.
2. With valves of large dimensions, the sling and the hooking of the load must be carried out by
using the appropriate tools (brackets, hook, fasteners, ropes) and load balancing tools in order to
prevent them from falling or moving during the lifting and handling.
1.3 Storage and Preservation before Installation

In case the valves have to be stored before installation, the storage has to be carried out in a
controlled way, and has to be performed in accordance with the following criteria:
1. The valves have to be stocked in a closed, clean and dry storage room.
2. The wedge must be in the closed position, and the end faces must be protected with plastic or
wooden discs fixed with straps. If possible, keep the original protection.
3. Periodical checks have to be carried out in the storage area to verify that the above mentioned
conditions are maintained.
For actuated valves, in addition to the above, please refer to the warnings in the manual of the actuator.
Installation
Sheet 1 of 4
2.1 Preparation before Installation

1. Carefully remove the valve from the shipping package (box or pallet) avoiding any damage to
the valve or, in case of automated valves, to the electric or pneumatic/hydraulic actuator or
instrumentation.
2. The valves are shipped with the ends protected with caps and a thin layer of protective grease.
Before installing the valve, remove the caps and clean carefully, then degrease both surfaces with
a solvent. Clean the inside of the valve by using an air line. Ensure that there are no solid objects
such as pieces of wood, plastic or packing materials within the valve or on the valve seat.
3. Confirm that the materials of construction listed on the valve nameplates (service and
temperature) are appropriate for the service intended and are as specified.
4. Define the preferred mounting orientation with respect to the system pressure. If any (see arrow
on the body), identify the upstream side (high pressure) and downstream side (low pressure).
Tyco reserves the right to change the contents without notice page 3
2.2 Installation Instructions
Gate valves are normally installed in horizontal pipe with vertical stem.
These valves can also be installed in vertical or horizontal pipe with stem other than vertical, but
this may require special construction depending on valve size, service condition, material and type
of operator.
For a correct operation, we recommend that the valve shall be installed and oriented as follows:
for gate valves with DN larger than 24” (unless specified in the order), the angle of inclination from
vertical shall not exceed 40°. Different positions from those indicated may cause a non-correct
valve operation, and/or a quick deterioration of the valve. Unless otherwise recommended, the
valve should be installed with the wedge in the closed position, to ensure that the seat ring in the
wedge is not damaged during installation. Particular care should be taken with those valves
equipped with ‘fail-open’ actuators. For operating temperatures above 200°C (392°F) thermal
insulation of the valve body is recommended. Handling and lifting of the valves during installation
MUST be performed following the same criteria and instructions described in previous points “1.2
Handling Requirements” and “1.3 Storage and Preservation before Installation”.
Important
After the valves installation and before the line testing, it is recommended to perform an
accurate cleaning of the lines to eliminate dirt and any foreign objects that could seriously
jeopardize the tightness between seat/disc and the correct operation of the valve.
Butt weld Valves

Position the valve and check the alignment with the pipe, then proceed with welding, in
accordance with the applicable welding procedure.
Flanged Valves
Place the valve between the two flanges of the pipe and put the seal gasket between the valve
flange and the pipe flange; make sure that it is correctly positioned. Then assemble the valve to
the pipe by the bolts which will be tightened crossing. Progressively reach the requested torque
value indicated by the Engineering Company that designed the plant.
After the valve installation on the line and before the line pressurization, the following activities
must be performed:
- all the threads plugs tightening shall be verified
Sheet 2 of 4
- the packing bolts must be tightened

- the torque of the body-bonnet bolts shall be verified
- the valve has to be fully stroke operated
- the paper protecting the stem must be removed; stem and bearings must be greased.
2.3 Valve Verification before Start Up

1. Tighten the packing just enough to prevent stem leakage. Over-tightening will decrease packing
life and increase operating torque.
2. Check the operation of the valve by stroking it to “full open” and “full close”.
2.4 Operations Instructions

The following instructions will help provide a satisfactory and long life service of the bolted bonnet
gate valves:
1. Make sure to perform periodic valve verification as described in paragraph 2.5.
2. In case of actuated valves always follow the specific instructions given by the actuator’s
manufacturer.
Tyco reserves the right to change the contents without notice page 4
2.5 Periodic Valve Verification during Service
A - Normal Check
1. Verify monthly that there is no leakage from packing or in the body/bonnet area. If the leakage
has been detected from the packing, tighten nuts according to the procedure described in Section
3.
If the leakage does not stop, follow the procedure for packing maintenance (3.1).
If the leakage has been detected from the body/bonnet, tighten the nuts.
If the leakage does not stop, follow the maintenance procedure for the replacement of the
body/bonnet gasket (3.2).
2. Every 2 / 3 months, depending on operating frequency, verify the greasing of bearings and
stem thread.
3. For actuated valves, in addition to the above, please refer also to the warnings in the actuator
manual.
Table I: Bolt Torque Figures for Body-Bonnet Flange Connections
B - Preventive Actions
1. Every 3 months verify the tightness of gland bolts.
2. Every 6 months on motorized valves and every 8 months on hand operated valves, grease
stem and bearings.
3. Every 12 months check the travel of the gland follower, setting a new packing when the end of
the travel is approaching.
4. Every 4 years disassemble the critical service valves and/or actuated valves, verifying the
sealing surfaces and lap them again when necessary. Substitute the bonnet gasket and the
packing, grease the stem.
5. For the actuator, proceed as indicated in its maintenance manual.
Maintenance
The bolted bonnet gate valves have been designed to require minimum maintenance.
This manual describes on site repairs as:
- Packing Maintenance
Sheet 3 of 4
- Bony/bonnet Flange Gasket Maintenance
3.1. Packing Maintenance

If leakage is observed through the packing, tighten the gland nuts slowly and evenly until the leakage stops.
To replace the packing proceed as follows:
1. Open completely the valve up to the backseat position.
2. Remove the nuts of the gland bolts
3. Lift the gland flange and the gland
4. Remove the worm-out packing using a hooking wire
5. For a better tightness, proceed to an accurate cleaning of the stem and stuffing box and
make sure there are no scratches or signs of seizing
6. The repacking shall be carried out by placing one ring at a time around the stem, inside the
stuffing box and by making sure that they are correctly oriented. Press it into the bottom.
7. When the stuffing box is filled, replace the gland and gland flange in their original position.
8. Tighten gland nuts.
9. Cycle the valve.
10. Pressurize the line.
11. If a leakage is detected, tighten the gland nuts slowly and evenly until the leakage stops.
3.2 Body-Bonnet Flange Gasket Maintenance

1. Before replacing the gasket, carefully clean the flange surfaces.
2. Place the gasket in its seat and begin to carefully position the bonnet flange. Position it
perfectly parallel to the gasket face; do not use the bolts to obtain this alignment.
3. In case the coupling is vertical (valve with horizontal stem), position the bonnet flange by
means of a hoist; lock it with four bolts placed at 90° on from the other and tighten them until
the flanges are perfectly coupled in their seat. Insert all the other bolts.
4. During tightening, make sure that the faces of the flanges remain perfectly parallel.
5. Tighten the bolts in the sequence. For a better performance of the joint, tighten again all the
bolts after the equipment has been pressurized.
Valve Removal and Maintenance Instruction

If the valve needs to be removed from the line for some extraordinary reason, the user should
ensure the following:
1. The valve is depressurized, drained and vent.
2. The pipe shall be cut as far away from the valve as possible (only for welded valves).
Grease and special tools
5.1 Greases
To lubricate the bearings on manual and gearbox operated valves, we suggest to use the grease
AGIP GRMUEP2 or an equivalent product.
For the lubrication of the stem thread, use the grease SIGNAL CEP 30.
5.2 Special Tools
No special tool required for the Maintenance Operation described in this Manual.
Sheet 4 of 4
ELECT.SIGN D:Cagliani C:Cagliani A1:Cagliani
IQ Range
Installation and
Maintenance Instructions
This manual contains important safety

information. Please ensure it is thoroughly
read and understood before installing,
operating or maintaining the equipment.
Publication number E170E3

Date of issue 10/05
The Rotork Setting Tool allows actuator control, indication and
protection functions to be configured to suit site requirements.
In addition, the new Setting Tool Pro also allows downloading
of datalogger and uploading/downloading of configuration
files. Files are transferred to and from the Setting Tool Pro via
Rotork Insight.
It is essential that all the actuator settings are checked for

compatibility with the valve, process and control system
requirements before the actuator is put into service. Please read
this publication.
Rotork Setting Tool Pro
When Rotork personnel or nominated agents are contracted to
carry out site commissioning and/or acceptance, documentation
of commissioned actuator configuration can be made available
for customer records.
Rotork Setting Tool

This manual provides instruction on: THE ROTORK IQ RANGE – THE FIRST VALVE ACTUATOR THAT YOU
CAN COMMISSION AND INTERROGATE WITHOUT REMOVING
* Manual and electrical (local and remote) operation. ELECTRICAL COVERS.
* Preparation and installation of the actuator onto Using the supplied infra-red Setting Tool to access the actuator set up
procedures, non-intrusive setting of torque levels, position limits and all
the valve.
other control and indication functions can be made safely, quickly and
conveniently, even in hazardous locations. The IQ allows commissioning
* Subsequent commissioning and adjustment of the and adjustment to be carried out with the main power supply to the
Basic Settings for correct valve operation. actuator switched on or off.
* Commissioning and adjustment of the Configuration Standard diagnostics access information about the control system, valve
and actuator status is in the form of display text and help screens.
Settings to suit site-specific control and indication
requirements. Setup, Alarm and Status text is available in English (default), Spanish, French
and German.
* Maintenance – Troubleshooting.
Instantaneous valve torque and position can be monitored on the actuator
* Sales and Service. with a single key press of the Setting Tool.
The on board Datalogger captures operational and valve torque data

enabling informed maintenance choices to be made. IQ Insight software
for PC and PDA allows the Datalogger to be interrogated, as well as the
Refer to Publication E180E2 for repair, overhaul and complete actuator set up to be configured and recorded.
spare part instructions.
The actuator containing the Setting Tool will be identified with a yellow
label on the terminal cover.
Visit our web site at www.rotork.com for more information on the IQ,
IQ Insight and other Rotork actuator ranges.
CONTENTS
Page Page Page

1 Health and Safety 2 5.5 IQM Modulating Actuators 12 9 Commissioning –
2 Storage 3
5.6 IQML Linear Drive Unit 12 Configuration Settings 31
5.7 IQML Adjusting Linear Stroke 13 Configuration Settings Contents 33
3 Operating your IQ Actuator 3 Default Options 63
6 Cable Connections 14
3.1 Operating by Hand 3
3.2 Operating Electrically 3
6.1 Earth/Ground Connections 14 10 Maintenance, Monitoring
3.3 Display – Local Indication 4
6.2 Removing Terminal Cover 14 and Troubleshooting 65
6.3 Cable Entry 14 10.1 Setting Tool Pro Download & Upload 68
3.4 Display Status Indication – Travel 5
6.4 Connecting to Terminals 15 10.2 Help Screens 71
3.5 Display Status Indication – Control 5
6.5 Replacing Terminal Cover 15 10.3 IQ Infrared Diagnostic & Configuration 76
3.6 Display Alarm Indication 5
7 Commissioning 16 10.4 Environmental 77
4 Preparing Drive Bush 7
4.1 IQ10 to IQ35 7
7.1 The Setting Procedure 16 11 Weights and Measures 78
7.2 The Rotork Setting Tools 17 Binary, Hexadecimal and Decimal
7.3 Entering the Actuator 20 Conversion Table 79
4.2 IQ10 to IQ35 8
Setting Procedure
Non-Thrust Base Type B 12 IQ Approvals 80
7.4 Setting Mode – Password 20
4.3 IQ40 to IQ95 8
Thrust Base Types A and Z 7.5 New Password 20
4.4 IQ40 to IQ95 9 7.6 Checking Mode 20
Non-Thrust Base Type B 7.7 Crossroad 21
7.8 The Actuator Display – 21
5 Mounting the Actuator 10 Setting/Checking Mode
5.1 Rising Stem Valves – Top Mounting 11 7.9 Returning to Valve Position Display 21
5.2 Valve with Gearbox – Side Mounting 12
5.3 Non-Rising Stem Valves – Top Mounting 12 8 Commissioning –
5.4 Handwheel Sealing 12
Basic Settings 22
Basic Settings Contents 23

1 Health and Safety
This manual is produced to enable a given in the applicable edition of the No inspection or repair should be than 150V AC but below 300V AC
competent user to install, operate, “IEE Wiring Regulations’’ should be undertaken unless it conforms to the (refer to actuator wiring diagram),
adjust and inspect Rotork IQ range applied. Also the user should be fully specific hazardous area certification the actuator installation altitude must
valve actuators. Only persons aware of his duties under the Health requirements. Under no circumstances be restricted to less than 2000m as
competent by virtue of their training and Safety Act 1974. should any modification or alteration be defined by BSEN 61010 or IEC 61010
or experience should install, maintain carried out on the actuator as this could (Safety Requirements For Electrical
For the USA: NFPA70, National Electrical
and repair Rotork actuators. Work invalidate the actuators hazardous Equipment for measurement, control
Code ® is applicable.
undertaken must be carried out in area approval certification. Access to and laboratory use).
accordance with the instructions in The mechanical installation should be live electrical conductors is forbidden
this and any other relevant manuals. in the hazardous area unless this is
WARNING: Enclosure Materials
carried out as outlined in this manual
The user and those persons working and also in accordance with relevant done under a special permit to work, IQ10 to IQ35 are manufactured from
on this equipment should be familiar standards such as British Standard otherwise all power should be isolated aluminium alloy with stainless steel
with their responsibilities under any Codes of Practice. If the actuator has and the actuator moved to a non- fasteners and the thrust bases are
statutory provisions relating to the nameplates indicating that it is suitable hazardous area for repair or attention. manufactured in cast iron.
Health and Safety of their workplace. for installation in hazardous areas then IQ40 to IQ95 enclosures are manufactured
Due consideration of additional the actuator may be installed in Zone WARNING: Motor Temperature in aluminium alloy and cast iron with
hazards should be taken when using 1, Zone 21, Zone 2 and Zone 22 (or Div Under normal operation the temperature stainless steel fasteners and the thrust
the IQ range of actuators with other 1 or Div 2, class I or Class II) classified of actuator’s motor cover surfaces can bases are manufactured in cast iron.
equipment. Should further information hazardous area locations only. It should exceed 60°C above ambient.
and guidance relating to the safe use not be installed in hazardous area The user must ensure that the operating
of the Rotork IQ range of actuators be locations with an ignition temperature WARNING: Thermostat Bypass environment and any materials
required, it will be provided on request. less than 135°C, unless suitability for If the actuator is configured to bypass surrounding the actuator cannot lead
lower ignition temperatures has been the motor thermostat then the hazardous to a reduction in the safe use of, or the
The electrical installation, maintenance protection afforded by, the actuator.
indicated on the actuator nameplate. area certification will be invalidated.
and use of these actuators should be
It should only be installed in hazardous Additional electrical hazards may occur Where appropriate the user must
carried out in accordance with the
area locations compatible with the gas when using this configuration. The ensure the actuator is suitably protected
National Legislation and Statutory
groups stated on the nameplate. user should ensure that any necessary against its operating environment.
Provisions relating to the safe use of
additional safety measures are considered.
this equipment, applicable to the site of The electrical installation, maintenance
installation. and the use of the actuator should be WARNING: Control and Indication WARNING: Operating by Hand
carried out in accordance with the code With respect to handwheel operation of
For the UK: Electricity at Work Where the actuator build allows remote
of practice relevant for that particular Rotork electric actuators, see warning
`Regulations 1989 and the guidance control and indication supplies higher
Hazardous Area certification. on p3.

2 Storage 3 Operating your
IQ Actuator
If your actuator cannot be installed 3.1 Operating by Hand To engage handwheel drive depress the When the selector is locked in the Local
immediately store it in a dry place until Hand/Auto lever into “Hand” position or Remote positions the Stop facility is still
you are ready to connect incoming and turn the handwheel to engage the available. The selector can also be locked
cables. WARNING clutch. The lever can now be released in the Stop position to prevent electrical
With respect to handwheel where it will return to its original operation by Local or Remote control.
If the actuator has to be installed but
position. The handwheel will remain
cannot be cabled it is recommended operation of Rotork electric
engaged until the actuator is operated
that the plastic transit cable entry plugs actuators, under no circumstances electrically when it will automatically
are replaced with metal plugs which are should any additional lever disengage and return to motor drive.
sealed with PTFE tape. device such as a wheel-key If required the Hand/Auto lever can
The Rotork double-sealed construction or wrench be applied to the be locked in either position using a
will preserve internal electrical handwheel in order to develop padlock with a 6.5mm hasp.
components perfectly if left more force when closing or
undisturbed. opening the valve as this may 3.2 Operating Electrically
cause damage to the valve and/or Check that power supply voltage agrees
It is not necessary to remove any with that on the actuator nameplate.
electrical compartment covers in order actuator or may cause the valve
to become stuck in the seated/ Switch on power supply. It is not
to commission the IQ actuator. necessary to check phase rotation.
backseated position.
Rotork cannot accept responsibility for Fig. 3.1
deterioration caused on-site once the Do not operate the actuator
covers are removed. electrically without first checking, Local Control
using the infra-red Setting Tool, With the red selector positioned at Local
Every Rotork actuator has been fully (anti-clockwise) the adjacent black knob
tested before leaving the factory to that at least the Basic Settings can be turned to select Open or Close.
give years of trouble free operation, have been made (refer to Section For Stop, turn red knob clockwise.
providing it is correctly commissioned, 8 page 22).
installed and sealed.
Selecting Local/Stop/Remote Remote Control
Operation Rotate the red selector to the Remote
The red selector enables either Local or position (clockwise), this allows remote
Remote control, lockable in each position control signals to operate the actuator.
Fig. 3 using a padlock with a 6.5mm hasp. Local Stop can still be used by turning
the red knob anti-clockwise.

3.3 Display–Local Indication description text in the lower display. Open Closed
The two tri-colour LED's will be Red, The two tri-colour LED's will be Green,
6. Battery Alarm Icon - This icon will be
the open symbol and "Open Limit" will closed symbol and "Closed Limit" will
displayed when a battery is detected as
be displayed be displayed.
low or flat. "Battery low" or "flat" will
also be displayed in the lower display.
7. IR Icon - This icon flashes during infra
red communication activity.
8. Percentage Open Icon - This icon will
be displayed when a percentage Open Open Limit Closed Limit
value is in the upper display.
The liquid crystal display screen has 2 Fig. 3.3 Fig. 3.5
modes of position indication:
Fig. 3.2 The Actuator Display With the main power supply switched
1. Valve position – power on Mid Travel off, the display screen is powered by
The display consists of: 2. Valve position – power off The two tri-colour LED's will be Amber, a battery and continues to display
percentage open value will be shown actuator position. However, the battery
1. Position Display - This is the main On power up the actuator’s liquid and "Stopped" will be displayed when
7-segment position display with icons. does not support screen back-lighting,
crystal display screen is back-lit with an there is no actuator movement. position indicator lamps or dot matrix
2. Text Display - This is a 2 line, 16 amber light and one of the indicator display.
characters dot matrix display which lamps will be on, dependent on
allows text to be used to compliment position. The display screen will show LED Indicators
the position display and icons. percentage open or an end of travel
symbol. (See Figs 3.3, 3.4 and 3.5)
3. Infra Red LED's. WARNING: Mid Travel LED
As standard, red lamp signifies valve colour may be affected by viewing
4. 2x Tri-colour LED's for position open, amber intermediate, and green Stopped angle and lighting level.
indication. lamp signifies valve closed. Open and
The Close LED colour can be changed
5. Alarm Icon - This will be displayed closed colour functions can be reversed
to red if required. The Mid Travel amber
for Valve, Control, and Actuator alarms. on request.
LED can be switched off if required.
Alarm indication is supported by fault Fig. 3.4
Refer to Section 9.16, page 62.

3.4 Display Status Indication • Timer Active Interrupter Timer option • Remote Control Remote control 3.6 Display Alarm Indication
– Travel enabled only. Interrupter Timer has selected – red selector.
The IQ display provides alarm indication
stopped the actuator mid travel for a
The IQ display provides real time status • Local Close Local close signal applied in the form of text and alarm icons.
indication. The top line of the text period equal to the set Timer Off
– black selector.
display is reserved for travel status time. Refer to 9.13 page 59. There are 2 alarm icons:
• Local Open Local open signal applied
indication. Fig 3.6 shows the travel
– black selector.
status example Closed Limit .
3.5 Display Status Indication • Remote Close Remote close (hardwired General Alarm:
– Control or analogue) signal applied.
The bottom line of the text display is
• Remote Open Remote open (hardwired Battery Alarm:
reserved for control status indication
or analogue) signal applied.
and is displayed for approximately 2
seconds after the control mode or • Remote ESD Remote hardwired
Closed Limit signal is applied. Fig 3.7 shows the emergency shut down signal applied.
control status example Remote Control . General Alarm
• Remote Bus Open Remote Bus * open
signal applied. The general alarm icon will be
Fig. 3.6 supported with text in the bottom line
• Remote Bus Close Remote Bus* signal indicating the particular alarm, or if
Available travel status conditions displayed: applied. more than one is present, each alarm
• Closed Limit Actuator has reached the • Remote Bus ESD Remote Bus* will be displayed in sequence.
set closed limit position. Closed Limit emergency shut down signal applied. Fig 3.8 shows the status example
• Open Limit Actuator has reached the Remote Control * Bus Control option fitted may be TORQUE TRIP CL .
set open limit position. Pakscan, Profibus, Modbus,
• Moving Open Actuator is traveling in Fig. 3.7 DeviceNet or Foundation Fieldbus.
the open direction. Refer to actuator wiring diagram.
Available control status conditions displayed:
• Moving Closed Actuator is traveling in • Local Control Local control selected -
the closed direction. red selector. Stopped
• Stopped Actuator has stopped in a • Local Stop Local stop selected – red TORQUE TRIP CL
mid travel position, indicated in the selector.
top display (%open). Fig. 3.8

Available alarm conditions displayed: Actuator Alarms • TORQ SENSOR FAIL Detected failure When a low or flat battery
in the torque sensing system alarm is displayed the battery
Valve Alarms • THERMOSTAT TRIP Motor thermostat
– contact Rotork. should be replaced immediately. It
has tripped due to the motor
• TORQUE TRIP CL tripped off on torque is essential that the correct battery
overheating. Operation is inhibited • EEPROM MISSING Contact Rotork
while moving in the close direction. type is fitted to maintain actuator
until the thermostat resets
• TORQUE TRIP OP tripped off on torque automatically when the motor cools. certification. Refer to page 65.
while moving in the open direction. Check actuator duty cycle against Battery Alarm After replacing a battery the
process requirements (running time, alarm icon will continue to be
• MOTOR STALLED no movement torque, ambient temperature).
detected after a signal to move. displayed until the next check and
• PHASE LOST (3-phase models only). may take up to 1 hour. Cycling the
Control Alarms The phase supply the actuator power will force a battery check
connected to terminal 3 is lost. and clear the alarm.
• ESD ACTIVE ESD signal applied. When
present the ESD signal overrides all
Operation is inhibited.
Open Limit
local and remote control signals. • 24V LOST The 24 volt customer BATTERY LOW PWR LOSS INHIBIT
Once the ESD action is carried out supply (terminals 4 & 5) has tripped.
operation is inhibited while the ESD Check remote control wiring. Supply Fig. 3.7 If, on power up, the actuator detects
signal is maintained. Refer to 9.3 is protected with a resettable fuse. a discharged battery and actuator
ESD Action page 36. The actuator checks the battery level power loss inhibit feature [OS] is
• LOCAL CONTROL FAIL Check operation
at approximately 1 hour intervals. The enabled (refer to page 61), both
• INTERLOCK ACTIVE Open and/or close of control selectors (black and red).
battery alarm icon is displayed when battery and general alarm icons will
interlocks are configured on and are • CONFIG ERROR There may be an error the actuator detects its battery as be displayed and the bottom line will
active. Refer to 9.3 Interlockpage 38. in the configuration (set up) of the being low and the display will indicate indicate alternately PWR LOSS INHIBIT
Operation in the direction of an actuator. Check and reset basic BATTERY LOW . and BATTERY FLAT . Electrical operation
active interlock(s) is inhibited. setting and check configuration will be inhibited. The battery must
Note that when conditional control is settings. If the battery is flat or missing the
be replaced and the limits must be
configured, an active interlock will display will indicate BATTERY FLAT .
• POS SENSOR FAIL Detected failure in reset. Refer to Section 10, page 66 and
not inhibit local control operation. Section 8, page 29.
the position sensing system – contact
Rotork.

4 Preparing Drive Bush
4.1 IQ10 to IQ35 2. Unscrew the bearing stop from the assembly working loose, as shown in
Thrust Base Types A and Z drive bush. Slide the bearing off the Fig 4.2. Refer to the table below for
drive bush. Keep the drive bush and required tightening torques.
Removal of Drive Bush for stop ring in a safe clean place.
Machining Socket set Allen key Torque Torque
3. For all sizes ensure the drive bush screw size bit size Nm lbs/ft
male thread (stop ring) is not
damaged during machining. For sizes M4 M2 2.2 1.62
IQ20, IQ25 & IQ35, ensure the O-ring
M6 M3 7.8 5.75
located in the drive bush is not
damaged during machining. Machine
drive bush to suit the valve stem,
allowing generous clearance on the
Fig. 4.1 Components of Type A screw thread for rising stem valves.
Thrust Base Re-assembly
bearing stop ring. The bearing stop ring 1. Remove all swarf from the drive
is locked with one socket set screw. bush, ensuring the O rings on the
drive bush and bearing stop ring
Fig. 4 Bronze Drive Bush Fitted into (where fitted) are undamaged, clean
IQ20, IQ25 and IQ35 have a thrust race and greased.
Thrust Taking Base
ball bearing within the steel bearing
Turn actuator onto its side, remove the housing, located on the drive bush 2. Slide the bearing assembly onto the Fig. 4.2
two cap-headed screws holding base and retained by the steel bearing stop drive bush and ensure it is fitted
plate onto thrust base, pull out the ring. The bearing is sealed within its down to the drive bush shoulder. 4. Refit the drive bush assembly into
drive bush complete with its bearing housing by O-rings located on the drive the base casting on the actuator,
3. Screw the stop ring with the locking ensuring that the slots in the drive
assembly. bush and on the bearing stop ring. The
socket set screw(s) uppermost on to bush are located into the drive dogs
Before machining the drive bush the bearing stop ring is locked with two
the drive bush until it comes to a of the hollow output shaft.
thrust bearing must be removed. socket set screws.
stop – hand tight and lock with the
IQ10, IQ12 and IQ18 actuators have a locking socket set screws. The 5. Refit the base plate and secure with
sealed thrust bearing located on the 1. Locate and loosen the locking socket locking socket set screws must be cap-headed screws.
drive bush and retained by the steel set screw(s) in the bearing stop ring. done up tight to prevent the

4.2 IQ10 to IQ35

Non-Thrust Base Type B
Undo the four set screws securing the
base plate to the gearcase and remove
the base plate.
The drive bush and its retaining clip can
now be seen.
Types B3 and B4 removal:
(refer to Fig. 4.3)
Fig. 4.4 Fig. 4.7 Type A Drive Bush
Using external circlip pliers, expand the Fig. 4.5 Locating Set Screw
circlip while pulling on the drive bush. Type B1 If the actuator has a type A drive bush
The drive bush will detach from the (Refer to Fig. 4.4) Loosen set screw and unscrew retainer (Fig. 4.7) this can be fitted in position
The procedure for removal and refitting using hammer and punch. Remove 1 or 2 to suit the position of the valve
actuator centre column with the circlip
of the B1 drive bush is the and same drive bush and machine to suit valve mounting flange.
retained in its groove. as for B3 and B4, However the circlip is stem or gearbox input shaft.
replaced with a custom spring clip. The
spring clip operates in the same manner Allow generous clearance on screw
as the B3/B4 circlip but is expanded thread for rising stem valves.
using long-nose pliers.
4.3 IQ40 to IQ95

Removal of Drive Bush for
Machining
Engage “hand” and turn handwheel
until retainer set screw is visible through
hole in actuator base. Fig. 4.8 Type A Drive Bush in
Position 1
Fig. 4.3
Fig. 4.6 Removal of Retainer

Fig. 4.9 Type A Drive Bush in Fig. 4.11 Type Z3 Drive Bush in
Position 2 Position 3
Fig. 4.13 B3/B4 Drive Bush
If the actuator has a type Z3 drive bush Re-Assembly
(Fig. 4.10) this can only be fitted below Having confirmed the position required,
the actuator base (Fig. 4.11). insert the machined drive bush ensuring
that the actuator output shaft dogs
are in full engagement with the bush. Fig. 4.12 Tightening Retainer Set
Fit drive bush retainer securely, turning Screw
clockwise until fully tightened using
hammer and punch. Rotate by hand Types B3 and B4
wheel to align retainer set screw with Identical drive bushes secured by cap
hole in the side of base and tighten to headed screws.
18.6 Nm / 13.7 lbsft. B3 is supplied pre-machined to ISO
5210 standard.
4.4 IQ40 to IQ95
Non-Thrust Base Type B B4 is supplied blank and must be
machined to suit the input shaft of the
Type B1 gearbox or valve that it will drive.
Fig. 4.10 Type Z3 Drive Bush Output shaft bored and keyed to ISO
5210 standard. There is no drive bush Fig. 4.14 B3/B4 Drive Bush in Situ
to machine.
10
5 Mounting the Actuator
Refer to Weights and Measures page 78 for actuator weight.

Ensure the valve is secure before fitting the actuator as the combination may be top
heavy and therefore unstable.
If it is necessary to lift the actuator using mechanical lifting equipment certified
slings should be attached as indicated in Fig.5 for vertical valve shafts and Fig.5.1
for horizontal shafts.
At all times trained and experienced personnel should ensure safe lifting,
particularly when mounting actuators.
WARNING:
The actuator should be fully supported until full valve shaft
engagement is achieved and the actuator is secured to the valve
flange.
A suitable mounting flange conforming to ISO 5210 or USA Standard MSS SP101
must be fitted to the valve.
Fig. 5
Actuator to valve fixing must conform to Material Specification ISO Class 8.8, yield
strength 628 N/sq mm.
WARNING:
Do not lift the actuator and valve combination via the actuator. Always
lift the valve/actuator assembly via the valve.
Each assembly must be assessed on an individual basis for safe lifting.
Fig. 5.1
11
5.1 Rising Stem Valves – Fit the machined drive bush into the Torque
Top Mounting thrust base as previously described,
lower the actuator onto the threaded Imperial Size Nm lbs/ft
a) Fitting the Actuator and valve stem, engage “hand” and wind
Base‑as a Combined Unit – 1/4 Hex 12.1 9
the handwheel in the opening direction
All Actuator Sizes to engage the drive bush onto the 5/16 Hex 24.3 17.9
stem. Continue winding until the 3/8 Hex 42.3 31.2
actuator is firmly down on the valve 7/16 Hex 67 49.4
flange. Wind two further turns, fit
securing bolts and tighten fully. 1/2 Hex 103.2 76.1
9/16 Hex 147.4 108.7
b) Fitting Thrust Base to Valve –
Actuator Sizes 10 to 35 only 5/8 Hex 205.3 151.4
Fit the machined drive bush into the Fig. 5.3 3/4 Hex 363.6 268.1
thrust base as previously described. Continue to turn actuator until fixing
Remove the thrust base from the 7/8 Hex 585 431.5
holes align. Using bolts supplied fix
actuator, place it on the threaded actuator to thrust base and tighten down 1 Hex 877.3 647.1
valve stem with the slotted end of the to the required torque, see table A. Torque
drive bush uppermost and turn it in Open valve by two turns and firmly
Fig. 5.2 the opening direction to engage the tighten down fixings onto valve flange Metric Size Nm lbs/ft
thread. Continue turning until the base to the required torque, see table B. M5-Hex 6.2 4.6
is positioned onto the valve flange. Fit
securing bolts but do not tighten at M6-Hex 10.8 7.9
this stage. Lower the actuator onto the M8-Hex 26.1 19.3
thrust base and rotate the complete
actuator until the drive dogs on the M10-Hex 51.6 38
actuator output shaft engage into the Torque M12-Hex 89.2 65.8
drive bush. Actuator flange should now Size Nm lbs/ft M16-Hex 219.8 162.1
be flush with base flange.
M8 Hex Head 14.8 10.9 M20-Hex 430.5 317.5
M12 Hex Head 50.2 37.1 M24-Hex 736.8 543.4
Table A Table B
12
5.2 Valve with Gearbox – 5.5 IQM Modulating Actuators 5.6 IQML Linear Drive Unit
Side Mounting The IQM range of actuators are suitable Consists of a lead screw assembly
Check that the mounting flange is at for modulating control duty of up to arrangement attached to the base
right angles to the input shaft, and 1200 starts per hour in accordance with of the actuator in order to provide a
that the drive bush fits the shaft and IEC 34-1 to S4 50%. linear output stroke between 8mm
key with adequate axial engagement. (3/8 in) minimum and 120mm (43/4 in)
Engage “hand”, offer up actuator to IQM actuators have a dynamic braking
maximum.
the input shaft and turn handwheel facility as standard. If mechanical
to align keyway and key. Tighten overrun of the actuator and valve prove The IQML can be supplied with or
mounting bolts. to be excessive for accurate control, the without a yoke mounting adaptor.
brake can be enabled by fitting a link to This adaptor consists of four pillars and
5.3 Non-Rising Stem Valves – the actuator terminal block as indicated a base flange to suit the valve.
Top Mounting by the wiring diagram. With dynamic
Treat as for side mounting except that braking enabled, motor heating effects
when thrust is taken in the actuator, increase and therefore the number
a thrust nut must be fitted above the of actuator starts should be reduced
drive bush and securely tightened. to prevent motor thermostat tripping
(refer to publication E410E for more
5.4 Handwheel Sealing information).
Ensure that sealing plug in centre of Commissioning of IQM range actuators
handwheel (or spindle cover tube is identical to the standard IQ (refer to Fig. 5.5 IQML without Yoke
depending on which is fitted) is sealed Sections 7, 8 and 9 commencing on
with PTFE tape and fully tightened, page 16).
ensuring that moisture does not
pass down the centre column of the
actuator.
Fig. 5.4 IQML with Yoke

13
5.7 IQML Adjusting Linear Stroke Turn the tubular down stop clockwise
With actuator securely fitted to valve, into the actuator until it comes to a
but with the linear drive disconnected, mechanical stop. If the valve must close
ensure valve is at its fully closed (down) onto its seat by “TORQUE ACTION”
position. then back off (anti-clockwise) the
down stop by one third of one turn
Remove cover tube from actuator (equivalent to 1mm). Run the lock nut
handwheel, locate the down stop down ontothe tubular down stop and
adjustment on the linear drive unit and tighten with two spanners. There is no
with two spanners loosen the lock nut, “up stop” (open) on the linear drive
run the lock nut and tubular down stop unit, the mechanical stop in the valve
to the end of the thread. will give this position. Refit the top
cover tube to the handwheel using PTFE
tape to seal the thread.
The linear drive unit is pre-packed with
grease type Rocol MTS 1000, use this or
an equivalent high temperature-bearing
grease.
A grease nipple is situated in the base
of the actuator to enable lubrication of
the lead screw. Periodically, depending
on usage and temperature, apply two
pumps of a grease gun.
Fig. 5.6 Down Stop two Spanners

Turn the actuator handwheel clockwise,
linear drive will move down towards
the valve spindle, couple linear drive to
valve spindle.
14
6 Cable Connections
6.1 Earth/Ground Connections Actuators containing a Setting Tool or

WARNING: A lug with a 6mm diameter hole is Setting Tool Pro fitted to the inside of
Ensure all power supplies cast adjacent to the conduit entries for the terminal compartment cover are
are isolated before removing attachment of an external protective identified with a self-adhesive yellow
actuator covers. earthing strap by a nut and bolt. An label on the outside of the terminal
internal earth terminal is also provided, compartment cover.
Check that the supply voltage agrees however it must not be used alone as
The wiring code card fixed in the cover
with that stamped on actuator the protective Earth Connection.
is particular to each actuator and must
nameplate. not be interchanged with any other
6.2 Removing Terminal Cover
A switch or circuit breaker must be actuator. If in doubt check the serial Fig. 6.2 - Actuator containing Rotork
Using a 6mm Allen key loosen the four
included in the wiring installation of number on the code card with that of Setting Tool Pro.
captive screws evenly. Do not attempt
the actuator. The switch or circuit the actuator.
to lever off the cover with a screwdriver
breaker shall be mounted as close as this will damage the “O” ring seal A plastic bag in the terminal
to the actuator as possible and shall and may damage the flamepath on a compartment contains:
be marked to indicate that it is the certified unit. • Terminal screws and washers.
disconnecting device for that particular • Spare cover “O” ring seal.
actuator. The actuator must be • Wiring diagram.
protected with overcurrent protection • Instruction book.
devices rated in accordance with
Rotork publication No. E130E Electric
motor performance data for IQ range
actuators.
WARNING:
Actuators for use on phase to Fig. 6.3
phase voltages greater than 600V
a.c. must not be used on supply 6.3 Cable Entry
systems such as floating, or earth- Fig. 6 Only appropriate certified Explosion-
phase systems, where phase to Fig. 6.1 - Actuator containing Rotork Proof entry reducers, glands or conduit
Setting Tool. may be used in hazardous locations.
earth voltages in excess of 600V
a.c. could exist.
15
Remove red plastic transit plugs. Make 6.5 Replacing Terminal Cover
cable entries appropriate to the cable Heading
type and size. Ensure that threaded Ensure cover “O” ring seal and spigot
adaptors, cable glands or conduit joint are in good condition and lightly
are tight and fully waterproof. Seal greased before re-fitting cover.
unused cable entries with a steel or
brass threaded plug. In hazardous areas ATTENTION: RED PLASTIC PLUGS IN CONDUIT ENTRIES ARE FOR TRANSIT ONLY.
an appropriately certified threaded FOR LONG TERM PROTECTION FIT SUITABLE METAL PLUGS.
blanking plug must be used.
6.4 Connecting to Terminals
On EExde enclosure units ATENCION: LOS TAPONES ROJOS DE PLASTICO EN LAS ENTRADAS DE CABLE
connections to the power and SON UNICAMENTE PARA TRANSPORTE. PARA PROTECCION PERMANENTE
control terminals must be made COLOCAR TAPONES METALICOS APROPIADOS.
using AMP type 160292 ring tabs
for power and earth terminals and ACHTUNG: DIE ROTEN PLASTIKSTOPFEN SIND NUR FÜR DEN TRANSPORT
AMP type 34148 ring tabs for the GEEIGNET. FÜR DAVERHAFTEN SCHUTZ SIND DIESE GEGEN GEEIGNETE
control terminals. BLINDSTOPFEN AUSZÜTAUSCHEN.
Refer to the wiring diagram inside the ATTENTION: LES BOUCHONS PLASTIQUES ASSURENT UNE PROTECTION
terminal cover to identify functions of TEMPORAIRE. POUR UNE PROTECTION DEFINITIVE UTILISER DES BOUCHONS
METALLIQUES.
terminals. Check that supply voltage
is the same as that marked on the
actuator nameplate.
Remove power terminal screen.
Begin by connecting these cables and
replace screen.
When all connections are made ensure
wiring diagram is replaced in the
terminal compartment.
16
7 Commissioning
7.1 The Setting Procedure 2. Configuration Settings Actuator Display

The Rotork IQ range of actuators is the Settings covering the control,
first that enables commissioning to be indication and optional 50
Position Display This may be an open or closed symbol
carried out without removing covers. equipment functions.
or a percentage open value.
Setting torque, limit and other functions m
is achieved by using the Infra-Red All IQ actuator functions are 50
Setting Tool. The Setting Tool is certified configured before dispatch to Torque and Position Torque
Refer to Section 10.
Intrinsically Safe to allow commissioning
in hazardous areas.
Rotork standard default settings
unless alternatives have been
m
All the commissioning functions are specified with the order. Should
Password P? k PC k Ir k tP
stored in non-volatile memory in the difficulty be encountered during m
actuator. The Setting Tool enables the
user to view all the functions in turn
commissioning the default Crossroad cr k
settings can be reinstated,
via the actuator display window. As
returning the actuator
m
each function is viewed its setting can
be checked and, if required, changed configuration to its original
within the bounds of that function. manufactured state. Site
Commissioning may be carried out with commissioning can then begin Basic Settings Configuration Settings
main power switched on or off. Refer again (refer to Section 9.18 page 63). Direction Indication Contacts
to page 22 for Power Off Setting.
Limit Actions Control Mode
The setting procedure is divided into The default function should be used Torque Values Options
two stages: with caution as settings selected after
manufacture may be essential for the Limit Positions Help Screens
1. Basic Settings safe operation of the valve and/or plant. Defaults
Settings for end of travel limit
actions, torque values, limit
positions etc.
Note: The Basic Settings must be commissioned first.
17
7.2 The Setting Tool (old version) 8 2

Specification 4
Enclosure IP67
6
Certification EEx ia IIC T4 (intrinsically safe)
FM, INT SAFE, Class I & II Div 1 Groups A B C D E F G, T4A
CSA, Exia, Class I, II Div 1 Groups A B C D
Power supply 9V Battery (supplied and fitted)
1
3
Name Instruction 5
7
3. - Key Decrease/change displayed function’s value or option setting Fig. 7.1 The Setting Tool
4. + Key Increase/change displayed function’s value or option setting Setting Tool Battery Replacement
5. Key Enter displayed value or option setting Battery status can be checked by looking at the Infra-red transmitter window while
depressing any Setting Tool button. A flashing red indicator should be seen.
* Pressing the two arrow keys together returns the actuator display to the position Battery replacement must be carried out in a safe area. To replace
indication mode the battery remove the six caphead screws in the back of the Setting Tool.
Remove the back cover to expose the battery.
Infra-red local operation (when enabled)
In order to maintain hazardous area certification fit only Duracell
5. Key Stop actuator
MN1604 or Rayovac Alkaline Maximum NoAL-9V battery types. Refit cover
6. Key Open actuator ensuring red indicator LED faces the transmitter window in the back cover.
7. Key Close actuator When a button is depressed the Setting Tool transmits the relevant instruction
to the actuator by infra-red pulses and must therefore be directly in front of the
8. Infra-red Transmitter Window actuator indicator window and at a distance no greater than 0.75m.
18
7.2 The Setting Tool Pro (new version) 2

3
Specification 12
Enclosure IP54 6
Manufacture This Setting Tool Pro has been constructed in accordance with: 7
EEx ia IIC T4 (intrinsically safe) 10
FM, INT SAFE, Class I & II Div 1 Groups A B C D E F G, T4 8
CSA, Exia, Class I Div 1 Groups A B C D
Power supply 2x 1.5V Batteries (supplied and fitted)
4
5
1
Name Instruction 11
Fig. 7.2 The Setting Tool Pro
2. i Key Display previous function up
4. o Key Display previous function across Infra-red local operation (when enabled)
5. - Key Decrease/change displayed function’s value or option setting 9. Key Stop actuator
6. + Key Increase/change displayed function’s value or option setting 10. Key Open actuator
7. m Key Initiate download/upload mode 11. Key Close actuator
8. Key Enter displayed value or option setting 12. Infra-red Transmitter Window
* Pressing these two arrow keys together returns the actuator display to the
position indication mode
19
Download / Upload Function Setting Tool Pro Battery Display Set-Up Mode The examples of displayed functions
This new feature has been introduced Replacement The Setting Tool and Setting Tool Pro Close Action , [C2] and Open Torque , [tO]
with the new Rotork Setting Tool arrow keys are used to access and are shown above. Note that a setting
Battery status can be checked by
Pro. It allows the user to download navigate through the actuator set-up option or value is highlighted.
looking at the Infra-red transmitter
datalogger files and download/upload window while depressing any Setting procedure using the actuator display. This instruction manual uses both code
configuration files. The new tool is Tool Pro button except the download Each actuator function with it's current and text for description.
weatherproof and intrinsically safe button. A flashing red indicator should setting is represented on screen by
and so it can be used safely in all be seen. a combination of code and text. The
environments. For more information Setting Tool change keys (+ and –)
refer to Section 10.1, page 68. Battery replacement must be allow the user to view the available
carried out in a safe area. To replace setting options.
the battery remove the six cap head
screws in the back of the Setting
Function Setting
Tool Pro. Remove the back cover to
Code Code
expose the battery.
In order to maintain hazardous
area certification fit only Duracell
MN1500 or GP Batteries GP15A Close Action
battery types. Refit cover ensuring
red indicator LED faces the Function Close on Torque Setting
transmitter window in the back cover. Option
When a button is depressed the

Setting Tool Pro transmits the relevant Function Setting
instruction to the actuator by infra-red Code Value
pulses and must therefore be directly in
front of the actuator indicator window
and at a distance no greater than
0.75m.
Open Torque
Function 40% Setting
Value
20
7.3 Entering the Actuator 7.4 Setting Mode – Password 7.5 New Password [PC] 7.6 Checking Mode
Setting Procedure To enable setting and adjustment of the To configure a new password, the The actuator function settings can be
With the actuator securely mounted actuator functions the correct password actuator must be in setting mode with checked without entering the correct
on the valve, the mains supply on and must be entered. The factory set (default) the password display – setting mode password. The settings can only be
Local control or Stop selected. password is [ld]. If the actuator has enabled – showing, viewed and not altered. The setting bars
previously been set with a site password will not be seen.
PRESS THE m KEY. this must be entered.
PRESS THE k KEY.
The actuator upper display will remain The display will change to [PC]. Using the
Use the + or - keys to scroll through the + or - key scroll through the available
the same and the lower display will available passwords 00–FF (hexadecimal).
change to Torque value. This will be passwords until the desired password is
With the correct password displayed press
represented by Torque = XX% and a displayed. Enter Password
the enter key.
bar graph. (For instantaneous torque PRESS THE KEY. ID Hex
& position monitoring, refer to Section PRESS THE KEY.
10, page 66.) Two “setting” bars will appear and will Password Display, Checking Mode
remain visible on every function display
Once the procedure has been completed
screen. In addition, "Password Correct"
PRESS THE m KEY. in the required mode
will be displayed for 3 seconds.
Change Password
The actuator display will change and IE Hex
PRESS THE m KEY.
the password protection display will The procedure branch [Cr] (crossroad)
be seen. Password Changed to [IE] display can now be seen (refer to Section
7.7 page 21).
NOTE: The new password becomes
Enter Password
effective the next time setting mode is
Password Correct
entered.
Enter Password Default Password,
ID Hex Setting Mode Enabled
The Actuator Function Settings

can be protected by the Use
of a Password
21
7.7 Crossroad [Cr] 7.8 The Actuator Display – In setting mode the Setting Tool + or 7.9 Returning to
Setting/Checking Mode - keys will cause the setting to be Valve Position Display
Actuator functions as laid out in the changed. In checking mode the settings There are five ways of returning to valve
Basic and Configuration commissioning cannot be altered. position display:
stages, can be individually displayed by
In setting mode, once displayed, a new 1. Approximately 5 minutes after the
Basic Setup using the Setting Tool arrow keys.
setting can be entered into the actuator last Setting Tool operation the
Config Setup The m arrow key will always display memory by pressing the key. display will automatically return to
the FIRST function on the next level The setting will flash off and back on, position display.
To access the Basic Settings press DOWN within the procedure. confirming its selection, and "Stored "
the arrow m key (refer to Section 8 will be displayed for 2 seconds in the 2. Press the m and k arrow keys
Commissioning Basic Settings page 22). The k arrow key will always display text display. together.
the NEXT function on the SAME level
To access the Configuration Settings and will wrap around the functions on 3. Press the m arrow key until the
press the arrow k key (refer to TOP LEFT display returns to position.
the same level. PORTION
Section 9 Commissioning Configuration 4. Select Remote control using the
The actuator display indicator lamps will Function e.g.
Settings page 31). red Local/Stop/Remote selector.
continue to indicate valve position but tC = Torque Close
will also flash during IR communication. 5. If you have the new Setting Tool
TOP RIGHT Pro then you can use the iarrow
Actuator functions are displayed in PORTION
code form in the top left portion of the key to return to position display.
Function Setting
liquid crystal display screen. Close Torque
e.g. Value = 40%
40%
The setting for the displayed function is
shown in the top right hand portion of LOWER DISPLAY
the screen. Depending on the actuator Function: Close Torque
function displayed, its setting may be Setting Value: 40%
an option or a value.
Text relating to the function and setting Typical Actuator Function Display
values will be displayed in the lower Setting Mode Enabled
display.
22
8 Commissioning –
Basic Functions
ELECTRICAL OPERATION MUST Power Off Setting
NOT TAKE PLACE UNTIL THE BASIC IQ allows settings to be viewed and
SETTINGS HAVE BEEN MADE AND set without main power. To enable this
CHECKED. function, engage handwheel drive and
rotate until the output drive moves
The actuator’s Basic Settings affect
(refer to page 3). The Setting Tool can
the correct operation of the valve by
now be used. As long as a Setting
the actuator. If the actuator has been
Tool key press takes place within the
supplied with the valve, the valve maker
30 seconds timeout period, Power
or supplier may have already made
Off Setting will remain enabled. If no
these settings.
infra-red Setting Tool communication
This instruction assumes setting mode takes place the display will return to
has been entered (refer to section 7.4 indicating position. The actuator must
page 20). then be operated by handwheel to
re-enable Power Off Setting.
With the actuator mounted on the Settings and operation must
valve, the power supply on and Local be verified by electric operation
or Stop control selected, point the
Setting Tool at the actuator indicator and function test of the actuator
window from a distance of no more to ensure correct operation.
than 0.75m. By pressing the m key
and, when appropriate, the k key,
it is possible to move through the
procedure, displaying the various
functions and their settings as shown
in Fig. 8.1 (refer to page 23).The
right-hand side of Fig.8.1 explains the
function of each LCD display.
Fig. 8
23
Function Description

50 Position Display REFER TO SECTION 7, COMMISSIONING
(This may be an open or closed symbol or a % open value.)
m m
50 Torque and Position Display
Torque
m m
P? k PC k Ir k tP Password k Password Change k IrDA k Torque Reference Profile
m m
Cr k Configuration Crossroad k Configuration Settings, refer to page 32.
C1 k C2 k C3 Direction to Close k Close Action k Open Action BASIC SETTINGS CONTENTS

m m page
tC k tO Torque Value Closing k Torque Value Opening C1 Direction to Close 22
C2 Close Action 23
m m
C3 Open Action 24
LC k LO Limit Closed k Limit Open tC Torque Value Closing 25
m m tO Torque Value Opening 26
50 Position Display LC Set Limit Closed 27
LO Set Limit Open 27
Fig. 8.1 Basic Setting Displays
24
C1 Direction to Close
The actuator can be configured to be Using the + or - key, display the Having ensured that the display
clockwise or anti-clockwise to close. character conforming to correct closing corresponds to the established
Manually operate actuator and valve direction. closing direction
to establish correct closing direction.
Conversion Handwheel direction labels
PRESS THE KEY.
are available. The displayed option will flash (stored),
50 PRESS THE k KEY.
Close Direction
m Clockwise
50 [C] in the Setting Field Indicating
Torque
Clockwise to Close
m
P? k PC k Ir k tP
m
cr
m Close Direction
Anticlockwise
c1 k c2 k c3
[A] in the Setting Field Indicating
m Anti-clockwise to Close
tC k tO
m
LC k LO
m
50
25
C2 Close Action
The actuator can be configured to close Using the + or - key, display the NOTE: When set to close on torque,
on torque for seating valves and limit Refer to valve manufacturer
required option. the actuator will apply the level of
for non-seating valves. for recommended setting.
torque as set for [tC] in seating the
In the absence of valvemaker valve (refer to [tC] page 27).
instructions refer to the following table
50 Valve type Close Open Close Action

m Close on Limit
Wedge gate “torque” “limit”
50 Globe “torque” “limit” [CL] in the Setting Field Indicating
Torque
Butterfly “limit” “limit” Close on Limit - default setting.

m Thru conduit “limit” “limit”
P? k PC k Ir k tP Ball “limit” “limit”
Plug “limit” “limit”
m Sluice gate “limit” “limit”
cr Penstock “limit” “limit”
Close Action
Parallel slide “limit” “limit”
m Close on Torque
c1 k c2 k c3 [Ct] in the Setting Field Indicating
m Close on Torque.
tC k tO
m
LC k LO Having selected the required option
m PRESS THE KEY.
50 The displayed option will flash (stored),
PRESS THE k KEY.
26
C3 Open Action
The actuator can be configured to Using the + or - key display the NOTE: When set to open on torque,
open on torque for back seating valves required option. the actuator will apply the level of
or limit for non back seating valves. torque as set for [tO] in back seating
the valve (refer to [tO] page 28).
for recommended setting. In the
absence of valvemaker instructions
set “Open Limit”. Open Action
Open on Limit
50 [OL] in the Setting Field Indicates
Open on Limit - defualt setting.
m
50
Torque
m
P? k PC k Ir k tP
Open Action
m Open on Torque
cr [Ot] in the Setting Field Indicates
m Open on Torque.
c1 k c2 k c3
m PRESS THE KEY.
tC k tO The displayed option will flash (stored),
m
PRESS THE k KEY.
LC k LO
m
50
27
tC Close Torque
The value of torque available in the Using the + and - keys, the display
close direction can be configured. recommended value. In the absence of
a recommended torque value, try a low
setting and increase until satisfactory
for recommended value. Close Torque
valve operation is achieved.
40%
The closing torque value can be varied
between 40% and Rated (100%), in If the actuator fails to 40% of Rated Torque
1% increments. complete a closed valve operation
reached (Torque Trip CL Alarm, page 5)
50 this may indicate a valve and/or
m process problem or change. It is the
responsibility of the user to ensure Close Torque
50 99%
Torque
the valve and process conditions are
m within specified operational limits
before increasing the Set Close 99% of Rated Torque
P? k PC k Ir k tP torque value.
m PRESS THE KEY.
cr The displayed value will flash (stored),
Close Torque
m indicating that it has been set.
100%
c1 k c2 k c3 Should the set level of torque be
developed in closing, the actuator will Rated Torque
m torque trip and stop.
tC k tO PRESS THE k KEY.
m NOTE: Rated torque is quoted on the
LC k LO actuator nameplate.
m
50
28
tO Open Torque
The value of torque available in the The opening torque value can be NOTE: Rated torque is quoted on the
open direction can be configured. varied between 40% and Rated, in 1% actuator nameplate. Boost torque is at
increments. In addition “Boost” can least 140% of Rated torque.
be configured when no open torque
for recommended value.
protection is required. PRESS THE KEY. Open Torque
100%
The displayed value will flash (stored),
BOOST SHOULD NOT BE indicating that it has been set. Rated
50 SELECTED WHEN THE ACTUATOR
HAS BEEN CONFIGURED TO OPEN
m ON TORQUE (refer to [C3] page 26)
50 UNLESS BACK SEATING AT RATED Should the set level of torque be
developed in opening, the actuator will Open Torque
Torque
TORQUE IS ACCEPTABLE.
m torque trip and stop. Boost
Using the + and - keys, display the
P? k PC k Ir k tP
recommended torque value.
PRESS THE m KEY. Boost
m
In the absence of a recommended
cr torque value, try a low setting and In checking mode, on pressing the m
m increase until satisfactory valve key after reviewing open torque setting,
operation is achieved. Open Torque the display will revert to valve position.
c1 k c2 k c3
40%
m If the actuator fails to
complete a open valve operation 40%
tC k tO
m reached (Torque Trip OP Alarm, page
5) this may indicate a valve and/or
LC k LO
process problem or change. It is the
m responsibility of the user to ensure
the valve and process conditions are Open Torque
50
within specified operational limits 99%
before increasing the Set Open 99%
torque value.
29
LC Set Limit Closed LO Set Limit Open
NOTE: It is possible to set the Open With [LC] displayed 50 With [LO] displayed
Limit Position [LO] first.
m
50
50 Torque
m Set Close Limit

m Set Open Limit
Move to Close P? k PC k Ir k tP Move to Open
50
m
Torque
m Limit Closed Limit Open

Move valve manually to the closed
cr Move valve manually to the open
P? k PC k Ir k tP
m
position. Allow for overrun by m position. Allow for overrun by
winding actuator output open by winding actuator output closed by
cr 1/2 to 1 turn.
c1 k c2 k c3 1/2 to 1 turn.
m PRESS THE KEY.

m
PRESS THE KEY.
c1 k c2 k c3
tC k tO
The two bars will flash (stored) and the The two bars will flash (stored) and the
m closed indicator lamp will illuminate, m open indicator lamp will illuminate,
indicating closed limit position has been LC k LO indicating open limit position has been
tC k tO set. set.
m m
PRESS THE k KEY. 50 PRESS THE m KEY.
LC k LO To check closed limit position hand The open symbol (refer to Fig. 3.3.
m wind valve open until the amber lamp page 4) should now appear.
illuminates. Wind valve back closed NOTE: When in checking mode Set
50 until the closed lamp illuminates. Limit Open [LO] does not appear.
NOTE: When in checking mode Set

Limit Closed [LC] does not appear.
30
Return to
Positional Display
50 If the procedure has been followed as
described, the positional display will
m indicate that the actuator is in the open
50 position.
Torque
m Select Remote control momentarily,

using the red selector to exit setting
P? k PC k Ir k tP procedure and then select required
control: Local, Stop or Remote.
m
With the correct settings made electric
cr
operation can now be carried out
m safely.
c1 k c2 k c3
m
tC k tO
m
LC k LO
m
50
31
9 Commissioning –
The Configuration Settings can be Power Off Setting
configured to suit site control and IQ allows settings to be viewed and
indication requirements. It is important set without mains power. To enable
that Basic Settings such as limits and this function, engage handwheel drive
torque switch settings are set before and rotate until the output drive moves
work commences on commissioning by one turn (refer to page 3).The
the Configuration Settings (refer to Setting‑Tool can now be used. As
page 22). long as a Setting Tool key press takes
place within the 30 seconds timeout
The layout of the Configuration
period, Power Off Setting will remain
Settings accessed with the Setting Tool
enabled. If no infra-red Setting Tool
are detailed in Fig. 9.1. To successfully
communication takes place the display
commission the Configuration Settings,
will return to indicating position. The
information about the site or process
actuator must then be operated by
control system will be required.
handwheel to re-enable Power Off
The supplied actuator Wiring Diagram Setting.
details control and indication devices
fitted to the actuator along with Settings and operation must
terminal connection detail and standard be verified by electric operation
remote control wiring systems.
and function test of the actuator
to ensure correct operation.
Fig. 9
32
50 Positional Display
m
Torque
IrDA Torque Reference

m comms Profile
P? k PC k Ir k tP
m Contact Function Value Contact Form
cr k Contact S1 r1 k r1 k r1

m m
Primary
m
Functions
m
m ESD ESD Thermostat ESD Overide ESD Override Maintained 2-wire External Conditional Torque Switch
ESD Action Contact Type Bypass Interlocks Local Stop Local Control Control Interlocks Control Bypass
Control Mode A1 k A2 k A3 k A4 k A5 k A6 k A7 k A8 k A9 k At
Configuration
m
Extra Indication 4-20mA Remote Interrupter Setting Tool Power Loss Choose Mid-Travel
Contacts CPT Control Source Timer Local Control Inhibit LED Colour LED Language
Option Selection OE k OI k Od k OJ k Or k OS k OH k OU k UL
m
Option Functions – If Analogue, Bus System or Interrupter Timer control options are fitted their appropriate set-up screens will be automatically inserted here.
m
Software Option 1 Option 2 Service
Version Version Version Reset Password
Service Mode Un k UI k U2 k Ur k UP
m
Help Screens H1 k H2 k H3 k H4 k H5 k H6 k H7 k H8 k H9
m
Default Option d1 k d2
m
Return to Positional Display Fig. 9.1 Configuration Settings
33
9.1 Accessing the
CONFIGURATION SETTINGS Having established that the Basic In order to display the Configuration
Settings have been correctly set, the Settings it is necessary to press the m
page Configuration Settings can now be key until [Cr] appears.
configured to suit site control and
9.1 Accessing the Configuration Settings 33 If you have chosen to enter
indication requirements.
Configuration Settings in the checking
9.2 Indication Contacts S1, S2, S3 and S4 34 It is possible to move through the mode the display will be as Fig. 9.2.
9.3 Control Mode Configuration 36 various Configuration Settings as shown
If you have chosen to enter
9.4 Option Extra Indication Contacts S5–S8 39 in Fig. 9.1 using the k and m keys.
Configuration Settings in the setting
9.5 Option CPT (4-20mA Indication) 40 The actuator wiring diagram will mode the display will be as Fig. 9.3
indicate any options fitted. (refer to Section 7).
9.6 Option Folomatic (Analogue Position Control) 41
9.7 Remote Control Source 44 Options Setting Tool Local Control
[Or] and Power Loss Inhibit [OS] are
9.8 Bus System Option Pakscan 45 standard features, their use being
9.9 Bus System Option Modbus 48 optional.
9.10 Bus System Option Profibus DP 51 Basic Setup Basic Setup
Config Setup Config Setup
9.11 Bus System Option DeviceNet 54
9.12 Bus System Positioning Control Settings 57 Fig. 9.2 Fig. 9.3
9.13 Option Interrupter Timer 59
9.14 Setting Tool Local Control 61 PRESS THE k KEY.
9.15 Inhibit Operation After Power Loss 61
9.16 Indicator LEDs 62
9.17 Display Language 62
9.18 Default Options 64
10.2 Help Screens 71
10.3 IrDA Diagnostics and Configuration 76
34
9.2 Indication Contacts r1 Contact S1 - Function
S1, S2, S3 and S4
Indication contacts S1 [r1], S2 [r2], S3 [Ol] Open Interlock Active * [LP] Function not available for phases Using the + or - key display the desired
[r3] and S4 [r4] may each be set to trip [Cl] Close Interlock 1 & 2, only for phase 3. For phase loss function.
for any one of the following functions: detection on phase 1 & 2 please use
[lL] Interlock Active monitor relay PRESS THE KEY.
Code Function (as displayed) [AA] Actuator Alarm The displayed function will flash
** [24] Function not available if the 3
[Ht] Thermostat Tripped phase supply is lost. indicating that it has been set.
[CL] Closed Limit
[OP] Open Limit [LP] Lost Phase *
[Po] Position % Open [24] 24V Power Failure **
[rr] Motor Running [bA] Battery Low
[dC] Closing [rP] Relay Parity
S1 Function
[dO] Opening
Close Limit
[d?] Moving The S contact form can be set normally
[HA] Hand Operation open [no] or normally closed [nc]. Contact S1 Configured to Trip
[bL] Moving-Blinker The procedures for setting up contacts at Valve Closed Limit
S2, S3 and S4 are the same as those
[UA] Valve Alarm PRESS THE k KEY.
shown for S1.
[tC] Torque Trip Close (direction)
[tO] Torque Trip Open (direction) Unless specified with order, the
[tt] Torque Trip (any position) default settings for indication
[tl] Torque Trip Mid (travel) contacts are as follows:
[St] Motor Stalled S1 – [CL] Closed Limit [no]
[LS] Stop Selected
S2 – [OP] Open Limit [no]
[Lo] Local Selected
[rE] Remote Selected S3 – [CL] Closed Limit [nc]
[CA] Control Alarm S4 – [OP] Open Limit [nc]
[ES] ESD Active
35
r1 Contact S1 - Value r1 Contact S1
Contact Form
This screen will only display if relay Use the + or - keys to select between
function is set to [P0] Position Open . [nO] Normally Open and [nC] Normally
When the S contact function is set to
Closed .
[P0], the required intermediate position PRESS THE KEY.
value must be set.
No other contact function requires indicating that it has been set.
a value to be set.
The value can be set from 1% open to
99% open in 1% increments.
Using the + or - key, display the
required value. S1 Contact
Normally Open
PRESS THE KEY.
The displayed value will flash (stored) Contact S1 Configured as a
indicating that it has been set. Normally Open Contact
NOTE: If function [PO] Position Open
is selected and it is configured as a
normally open contact it will make at
the set value with the actuator moving
S1 % Position in the open direction.
25% To access S2–S4
Value Set to Indicate PRESS THE m KEY.
25% Open
PRESS THE k KEY.

36
9.3 Control Mode A1 ESD Action A2 ESD Contact Type A3 ESD Override
Configuration Thermostat
The Control Mode Configuration affects An active ESD signal applied to the The default setting for ESD Contact The default setting for ESD Override
how the actuator will respond under actuator will override any existing or Type is [nO] Normally Open . Thermostat is [OF] No during ESD.
conditions of emergency shut down, applied local or remote control signal. The thermostats remain in circuit and
For actuators set to ESD [nO] Normally
local control, remote control interlocks, ESD can be configured to override the enabled during ESD.
and 2-wire remote control. Also motor thermostat, active interlocks or
Open the ESD Signal must be applied
to activate the ESD command. For ESD The motor thermostats can be bypassed
included is an unseating torque switch local stop selection. Refer to A3, A4
[nC] Normally Closed the signal must be during ESD as a factory set, hard-
bypass function. Unless specified with and A5.
removed to activate the command. wired option only. Contact Rotork for
order, the control mode configuration
The default action under an active ESD Press the + or - key to choose the information.
will be set as shown for default
signal is to stay put [SP] Stay Put . contact type.
configuration on page 63. Danger: Actuator hazardous
Press the + or - key to select the PRESS THE KEY. area certification is invalidated
If it is necessary to change the
configuration follow the instructions in
required ESD action: while the thermostats are
The displayed option (stored) will flash
bypassed.
this section. [OF] Off on ESD indicating that it has been set.
[A3] should be set to reflect the factory
There are 10 configurable control [CL] Close on ESD
set configuration of thermostat bypass.
functions:
[SP] Stay Put on ESD
During an ESD event:
Code Function (as displayed) [OP] Open on ESD
[A3] = [OF] No , thermostats enabled
ESD Contact Type
[A1] ESD Action PRESS THE KEY. Normally Open [A3] = [On] Yes , thermostats bypassed
[A2] ESD Contact Type The displayed option will flash (stored)
indicating that it has been set. Actuator Responds to a Normally
[A3] ESD Override Stat Open ESD Contact (Signal Applied)
[A4] ESD Override Interlocks
[A5] ESD Override Local Stop ESD Override
[A6] Maintain Local Control Stat: No
[A7] 2-wire Remote Priority ESD Action
Close
[A8] Interlocks
[A9] Conditional Control
[At] Torque Switch Bypass.
37
A4 ESD Override A5 ESD Override A6 Maintain A7 2-wire Remote
Interlocks Local Stop Local Control Priority
The default setting for ESD Override The default setting for ESD Override The default setting for Local Actuator The default setting for 2-wire Remote
Interlocks is [OF] No . ESD action will not Local Stop is [OF] No . ESD will not Pushbutton control is self-maintained Priority is [SP] Stay Put . If an open and
override an active interlock applied to override local stop when selected. [On] Yes . closed remote control signal are applied
the actuator. simultaneously the actuator will stay
If an applied ESD signal is required to If non-maintained actuator pushbutton
put (stop if running). Refer to actuator
If an applied ESD signal is required to override local stop causing the ESD control is required (jogging, inching,
wiring diagram or publication E120E.
override active interlocks causing the action as set for A1, press the + or - key. push to run), press the + or - key. The
ESD action as set for A1, press the The display will change to [On] Yes . display will change to [OF] No .
+ or - key. The display will change to
PRESS THE KEY. PRESS THE KEY. Use the + or - key to select the
[On] Yes .
required priority:
PRESS THE KEY.
indicating that it has been set. indicating that it has been set. [OP] Open
[SP] Stay Put
[CL] Close
PRESS THE KEY.
ESD Override Maintain Local
Local Stop: No Control: Yes
ESD Override
Interlocks: No
2-Wire Remote
Priority: Stay
2-wire Control – Stay Put Priority

38
A8 Interlocks A9 Conditional Control At Torque Switch Bypass
Actuators are delivered with the Where a high level of safety integrity The default setting for Torque Switch
interlock facility disabled [OF] Disabled . is required, Conditional Control can Bypass is [OF] Off , the torque switches
Refer to the actuator wiring diagram or be configured. In this mode two are not bypassed during the unseating
publication E120E for interlock control discreet signals are required for remote movement.
circuits. operation. Remote control will be
To bypass the torque switches during
conditional on both a control signal
To enable remote external interlocks the unseating movement press the +
(open or close) and the appropriate
press the + or - key. or - key.
interlock signal being applied
The display will change to [On] Enabled . simultaneously. Failure of either or a The display will change to [On].
spurious signal will not cause operation.
Interlocks [A8] must be set [On]
The displayed option will flash (stored) Enabled . Interlock signals are not The displayed option will flash (stored)
indicating that it has been set. required for local operation. indicating that it has been set.
The default setting for conditional The torque switches will be bypassed
control is [OF] Disabled . To enable from closed limit to 5% open when
conditional control press the + or - key. opening and from open limit to 95%
The display will change to [On] Enabled . when closing. Bypassing the torque
Interlocks switches makes torque in excess of
Disabled PRESS THE KEY. rated and up to actuator stall available
for unseating a ‘‘sticky’’ valve. Outside
these positions the torque setting will
revert to the values set for [tC] Close
Note: If interlocking is required in only
Torque , see page 27 and [tO] Open
one direction, it will be necessary to
Torque , page 28.
connect a link between the actuator
terminals associated with the other
direction. Refer to wiring diagram.
Conditional
Control: Disabled
Torque Switch
Bypass: Off
39
9.4 Option Extra OE Display Extra Contact
Indication Contacts Set-up Screens
Extra indication contacts S5 [r5], S6 The action of turning on the Extra
[r6], S7 [r7] and S8 [r8] are available as Contact Option makes an additional
an option. series of set-up screens available
Check actuator circuit diagram for
inclusion.
When the Extra Contact Option is
included the set-up procedure and
Extra Contacts Extra Contacts
available contact functions for S5 – S8
Menu: On Menu: Off
are identical to S1–S4 (refer to Section
9.2 page 34).
Press the + or - key to select the Extra
Unless specified with order the default
Contact Option set-up screens [On].
setting for the extra indication contacts
will be as follows: PRESS THE KEY.
S5 [r5] Close limit The displayed option will flash (stored)
S6 [r6] Open limit
PRESS THE m KEY TO ACCESS S5
S7 [r7] Torque trip mid
TO S8 SET-UP DISPLAYS.
S8 [r8] Remote selected
The procedure for setting S5 to
NOTE: If the Extra Contact Option is S8 is the same as that for S1 to S4
not included in the actuator build, any (refer to Section 9.2 page 34).
settings made for S5–S8 will have no
effect on the indication output of the
actuator.
40
9.5 Option CPT [OI] –
4-20mA Indicator
Setting instructions for actuators NOTE: If the actuator has options
including a CPT providing 4-20mA Folomatic and CPT, redefining the
analogue position feedback. CPT, will require the Folomatic to be
recommissioned (refer to Section 9.6
The CPT is an optional extra. It may be Folomatic [OI] page 41).
internally or externally powered.
Check wiring diagram for inclusion and
connection details.
Analog Feedback
CL=4ma OP=20mA
With [HI] Displayed, the CPT operates

Close=4mA , Open=20mA
If Close=20mA , Open=4mA is required, use
the + or - key to change to [LO].
PRESS THE KEY.
indicating that the option has been set.
41
9.6 Option Folomatic – OI Folomatic Feedback FI Analogue
Analogue Control Signal Type
Setting instructions for This instruction lists the Folomatic Before commissioning of the Folomatic Using the + or - key select [ l] Current
actuators including a Folomatic function displays in their sequence and functions can begin, the Folomatic for current input signal or [ U] Voltage
proportional controller for use in assumes that all Folomatic functions are Feedback must be set to suit the for voltage input signal.
to be checked/set. applied set point signal.
analogue valve position control.
The actuator should be selected in Local
The Folomatic is an optional or Stop with the analogue input signal
control device. Check actuator connected to terminals 26(+ve) and
wiring diagram for inclusion. 27(–ve) (refer to wiring diagram).
Analog Signal
Analog Feedback
Before setting the parameters for Type: Current
CL=4ma OP=20mA
Option Folomatic ensure Remote
Control Source [Od] has been With [HI] displayed, a 20mA signal will PRESS THE KEY.
selected to [bo] in Section 9.7. correspond to the valve opening.
If a high input signal is required to indicating that it has been set.
Folomatic set up screens will be correspond to valve closing use the
automatically displayed when the + or - key to change to [LO] CL=20mA . The signal type selected will determine
option is fitted. Refer to actuator wiring what is displayed on the input signal
diagram. PRESS THE KEY. range screen [Fr] Analog Signal .
indicating that it has been set. [Fr] Analog Signal .
If setting [OI] is modified after
commissioning the Folomatic, it will
be necessary to recommission the
Folomatic.
Press the m key to access the
Folomatic set-up display menus.
42
Fr Input FL Valve Position FH Valve Position Fd Deadband
Signal Range LOW Set Point HIGH Set Point Adjustment
Using the + or - key select for required If the actuator hunts or responds
signal within the range of 0–5mA or
APPLY MINIMUM APPLY MAXIMUM unnecessarily to a fluctuating input
volts, 0–10mA or volts or 0–20mA or SET POINT SIGNAL SET POINT SIGNAL signal the deadband must be increased.
volts (i.e. 4–20mA). Using the + or - key select: Using the + or - key select: If more accurate control is required the
deadband may be decreased.
If [FI] is set to current , mA ranges will be [ ] [ ] Closed = valve closed [ ] [ ] Closed = valve closed
displayed. If [FI] is set to Voltage , voltage [00] to [99] = percentage open [00] to [99] = percentage open Use the + or - key to select the
ranges will be displayed. deadband width. Range 00–99
[ ] Open = valve open [ ] Open = valve open
corresponds to 0–9.9% of setpoint
to correspond with the LOW set point to correspond with the HIGH set point signal.
signal. signal.
NOTE: Maximum deadband is 9.9%
of valve stroke. Normally, minimum
Analog Signal deadband should not be less than 1%.
Range: 4-20mA
0–20mA Range Selected

Position: Closed Position: Open
Deadband
1.2%
Analog Signal
Range: 0-20V The displayed value will flash (stored) The displayed value will flash (stored)
indicating that it has been set. indicating that it has been set. PRESS THE KEY.
0-20V Range Selected
Press the k key to display: Press the k key to display: The displayed value will flash (stored)
[FH] High Set Point Position . [Fd] Deadband . indicating that it has been set.
PRESS THE KEY.
indicating that it has been set. [Ft] Motion Inhibit Time .

[FL] Low Set Point Position .
43
Ft Motion Inhibit FA Action On Loss of FF Failsafe Action
Timer Adjustment Set Point Signal
The motion inhibit timer introduces Use + or - key to enable [On] or Failsafe action when [FA] Loss of Signal
a delay in the actuator response to disable [OF] action on loss of set point set to [On] Failsafe only.
a rapidly fluctuating input signal, signal.
preventing unnecessary movement. Use + or - key to select, on loss of
[On] – Failsafe as determined by [FF]. input signal:
Once the system stabilises the actuator
will respond to steady changes in the [OF] – Go to Low SP [Lo] – Go to Low SP position.
input signal as necessary. [SP] – Stay Put
Use + or - key to adjust motion inhibit [Hl] – Go to High SP position.
time in seconds: range 0–99. Normally
it is recommended that motion inhibit
time should not be set to less than 5 Loss of Signal
seconds (refer to note on page 61). Failsafe
Failsafe Action
Go to Low SP
PRESS THE KEY.
Motion Inhibit
Time: 05 seconds
PRESS THE KEY.
NOTE: Failsafe action “ON” will be
effective only for systems using an The displayed option will flash (stored)
offset or live zero signal range, for indicating that it has been set.
PRESS THE KEY. example 4–20mA.
Commissioning of the Folomatic is
The displayed value will flash (stored) [FF] will only be displayed if [FA] has now complete. Remote control may be
indicating that it has been set. been set to [On]. selected.
Press the k key to display: Press the k key to display:
[FA] Loss of Signal . [FF] Failsafe Action .
44
9.7 Remote Control Source Od Remote Control Source
The available forms of remote control The setting of Remote Control Source To change the remote source press the
are listed below: will be determined by the option that + or - key until the required setting is
has been fitted, if any. displayed.
1 - Standard hardwired control
2 - Analogue control-Option Folomatic [rE] Hard-Wired Only : Pushbutton/relay PRESS THE KEY.
3 - Network control including: contact control.
Option Pakscan
[oP] Network : Pakscan, Profibus, indicating that it has been set.
Option Modbus Modbus, Foundation Fieldbus or
Option Profibus DeviceNet control.
Option Foundation Fieldbus
Option DeviceNet [bo] Folomatic : Analogue Proportional
control.
The setting for Remote Control Source
[OF] Remote Disabled : Remote control Control Type
will depend on the type of remote
Hard-wired Only
control required and the option disabled.
specified and fitted. Check actuator Standard Hardwired
circuit diagram for remote control form. Remote Control
45
9.8 Bus System PA Pakscan Node Pb Pakscan
Option Pakscan Address Baud Rate
Setting instructions for actuators The actuator Pakscan Field Control Unit The actuator Pakscan Field Control Unit
including an optional Pakscan Field must be allocated a unique loop node baud rate must be set to the loop baud
Control Unit – check wiring diagram for address. rate. For a Pakscan 2-wire control loop
inclusion. the selected baud rate must be common
The actuator must be in “Loopback” Baud Rate
to the master station and all the field
Before setting the parameters for and isolated from Pakscan loop traffic
control units included in the loop. 2400 Baud
for its address to be set or changed.
Option Pakscan ensure Remote
Loopback can be achieved in two ways: The actuator must be in “Loopback”
Control Source [Od] has been and isolated from Pakscan loop traffic
1. Turn OFF the master station. PRESS THE KEY.
selected to [oP] in Section 9.7. for its baud rate to be set or changed.
(refer to page 44) 2. Isolate the actuator from the The displayed option will flash (stored)
Loopback can be achieved in two ways: indicating that it has been set.
1. Turn OFF the master station. Press the k key to display:
required loop address. 2. Isolate the actuator from the [PF] Aux I/P Mask .
Address to be set within the range
01-240 (01–F0 Hexadecimal). (refer to
table on page 79).
required baud rate.
[01] = 110 baud
Node Address [03] = 300 baud
Hex 01 : Dec 001 [06] = 600 baud
[12] = 1200 baud
PRESS THE KEY.
[24] = 2400 baud
[Pb] Baud Rate .
46
PF Pakscan Remote
Auxiliary Input Mask
Pakscan card. It is also possible to have a combination of both remote control and Any function bit set to ‘‘0’’ indicates that the particular aux input is to be treated as
volt-free inputs to provide, for example, open and close control as well as a high a digital signal for field status reporting, e.g. a level switch or motor running status.
and low tank level alarm indication, supplied via an external transducer.
The hexadecimal number displayed under PF can be considered as a ‘‘software "1" and a closed contact is reported as a logic ‘‘0’’ (i.e. this will invert the input).
mask’’. It is this mask that tells the Pakscan card what type of input to expect,
input).
(When used for digital signal inputs they are simply designated as AUX 4 to AUX 1) 4. Stop (Maintain) Control
When energised this will make the Aux input Open/Close/ESD control push-to-run,
(non-maintained).
When de-energised, the Aux input Open/Close/ESD control will be maintained.
47
PF Pakscan Remote PF Pakscan Remote
For Pakscan this is [oP] Network .
Examples
and Stop/maintain is NC. Bits: 0000 1111
Aux I/P 4321 Auxiliary Input Mask [OF]

Function 1111 =F PRESS THE KEY.
Invert 0011 =3 i.e. set [PF] to [F3] The displayed option will flash (stored)
2. Open and close control is required along with 2 inverted digital signal inputs
(Note that with this setting the open and close commands will be maintained.) For Pakscan module positioning settings
[OF], refer to page 57.
Aux I/P 4321
If Pakscan positioning control is
Function 0011 =3 required, PRESS THE m KEY.
Invert 0011 =3 i.e. set [PF] to [33] Display [FL] Low Set Point Position
3. Only an ESD input is needed. The requirement is for push to run control with a (refer to page 57).
NO contact input.
Aux I/P 4321
Function 1100 =C
Invert 1000 =8 i.e. set [PF] to [C8]
48
9.9 Bus System PA Modbus Node Pb Modbus Baudrate
Option Modbus [OP] Address
Setting instructions for actuators The Modbus module must be allocated The Modbus module must be set to the
including an optional Modbus RTU a unique address. RS485 highway baudrate. To set the
module – check wiring diagram for baudrate the Modbus module must be
To set the address the Modbus module
inclusion. isolated from the host by disconnecting
must be isolated from the host by
the RS485 highway or turning off the
disconnecting the RS485 highway or
Before setting the parameters for host device.
turning off the host device.
Option Modbus ensure Remote Using the + or - keys display the
required baudrate:
selected to [oP] in Section 9.7. [01] = 110
(refer to page 44). Address to be set within the range (01-
247 to F7 Hexadecimal). If an address [03] = 300 [06] = 600
value outside this range is entered, the [12] = 1200 [24] = 2400
The actuator power must be address set will revert to 01 (for 00) or [48] = 4800 [96] = 9600
cycled for the changes to take effect. F7 (for value above F7). [19] = 19200 [38] = 38400
[57] = 57600 [11] = 115200
Node Address
Hex 01 : Dec 001 Baud Rate
2400 Baud
PRESS THE KEY.

PRESS THE KEY.
indicating that it has been set. The displayed option will flash (stored)
[Pb] Baud Rate . Press the k key to display:
[PF] Aux I/P Mask .
49
PF Modbus Remote
Auxiliary Input
The IQ actuator has the facility to accept 4 auxiliary inputs (AUX1 – AUX4). These Rules
Modbus module. It is also possible to have a combination of both remote control Any function bit set to ‘‘0’’ indicates that the particular aux input is to be treated as
The hexadecimal number displayed under PF can be considered as a ‘‘software ‘‘1’’ and a closed contact is reported as a logic ‘‘0’’ (i.e. this will invert the input).
mask’’. It is this mask that tells the Modbus module what type of input to expect,
input).
(When used for digital signal inputs they are simply designated as AUX 4 to AUX 1.) 4. Stop (Maintain) Control
50
PF Modbus Remote PP Modbus Parity
5. Remote I/P Setting Using the or keys display the required Where Modbus parity bit detection is
Ensure that the correct [Od] Control Type setting is selected (refer to page 44). mask setting. used the module must be set with the
parity bit setting of the host.
For Modbus this is [OP] Network .
The factory default for [PF] Aux I/P Mask is [OF] 0000 1111 . required parity bit:
Examples [no] None (no) parity bit
Bits: 0000 1111 [En] Even parity bit
[Od] Odd parity bit
Aux I/P 4 3 2 1
Function 1 1 1 1 =F
PRESS THE KEY.
(Note that with this setting the open and close commands will be maintained.) Modbus Parity
Press the k key to display: None
Aux I/P 4 3 2 1 [PP] Modbus Parity .
Function 0 0 1 1 =3 No Parity Bit
PRESS THE KEY.
NO contact input. The displayed option will flash (stored)
Aux I/P 4 3 2 1
Function 1 1 0 0 =C For Modbus module positioning
Invert 1000 = 8 i.e. set [PF] to [C8] setting [OF] (refer to page 57).
If Modbus positioning control and
action on loss of communication are
required, PRESS THE m KEY.
Display [FL] Low Set Point Position
(refer to page 57).
51
9.10 Bus System PA Profibus Node
Option Profibus DP [OP] Address
Setting instructions for actuators The Profibus DP module must be
including an optional Profibus DP allocated a unique address.
To set the address the Profibus module
inclusion.
must be isolated from the host by Node Address
disconnecting the RS485 highway or Hex 01 : Dec 001
Before setting the parameters for turning off the host device.
Option Profibus ensure Remote
Using the + or - keys display the PRESS THE KEY.
selected to [oP] in Section 9.7. The displayed option will flash (stored)
(refer to page 44). Address to be set within the range indicating that it has been set.
(01-126 to 7E Hexadecimal) (refer to
page 79 for conversion). If an address Press the k to display:
Any settings made locally at value outside this range is entered, the [Pb] Baud Rate .
the actuator may be overwritten by address set will revert to 01 (for 00) or
the host on startup unless the GSD 7E (for value above 7E). [Pb] has no relevance for the
files are locked on the Profibus card. Rotork Profibus DP Mk.2 card.
from www.rotork.com Therefore, if the Rotork Profibus DP Mk.2
card is fitted, press the k to display:
[PF] Aux I/P Mask .
52
PF Profibus Remote
Auxiliary Input
Profibus module. It is also possible to have a combination of both remote control Any function bit set to ‘‘0’’ indicates that the particular aux input is to be treated as
The hexadecimal number displayed under PF can be considered as a ‘‘software ‘‘1’’ and a closed contact is reported as a logic "0" (i.e. this will invert the input).
mask’’. It is this mask that tells the Profibus module what type of input to expect,
closed (refer to page 79 for Binary, Hexadecimal and Decimal Conversion Table). ‘‘0’’ and a closed contact is reported as a logic ‘‘1’’ (i.e. this gives a noninverting
input).
Bit 1 (AUX1) – Open open or close the valve (refer to page 36).
(When used for digital signal inputs they are simply designated as AUX 4 to AUX 1.) 4. Stop/Maintain Control
When energised this will make the Aux input Open/Close control push to run When
de-energised, the Aux input Open/Close control will be maintained. ESD is always
push to run (non maintained).
53
PF Profibus Remote PF Profibus Remote
5. Remote Source Setting [Od] Using the + or - keys display the
For Profibus this is [OP] Network .
Examples
Aux I/P Mask
1. The full range of remote controls is needed. Open and Close are NO and ESD
Bits: 0000 1111
Aux I/P 4 3 2 1
(Note that with this setting the open and close commands will be maintained.)
If Profibus positioning control and
Aux I/P 4 3 2 1 action on loss of communication are
Function 0 0 1 1 =3 required, PRESS THE m KEY.
Invert 0011 = 3 i.e. set [PF] to [33] Display [FL] Low Set Point Position
(refer to page 57).
NO contact input.
Aux I/P 4 3 2 1
Function 1 1 0 0 =C
54
9.11 Option DeviceNet PA DeviceNet Node Pb DeviceNet Baudrate
Address
Setting instructions for actuators The DeviceNet module must be The DeviceNet module must be set to
including an optional DeviceNet DFU allocated a unique address. the DeviceNet highway baudrate.
Using the + or - keys display the Using the + or - keys display the
inclusion.
required address. required baudrate:
Before setting the parameters for Address to be set within the range (01- [01] = 125 k baud
Option DeviceNet ensure Remote 63 to 3F Hexadecimal). See page 79 for
[03] = 250 k baud
Control Source [Od] has been conversion. If an address value outside
selected to [oP] in section 9.7. this range is entered, the address set [06] = 500 k baud
(refer to page 44). will revert to 01 (for 00) or 3F (for value
above 3F).
Node Address Baud Rate

Hex 01 : Dec 001 500 baud
PRESS THE KEY.

PRESS THE KEY.
The displayed option will flash (stored) indicating that it has been set.
Press the k key to display: [PF] Aux I/P Mask .
[Pb] Baud Rate .
55
PF DeviceNet Remote
Auxiliary Input
are used when supplementary remote control or volt free digital auxiliary inputs are
required in addition to the standard control and feedback features incorporated 1. Function bit set to ‘‘0’’
into the DeviceNet module. It is also possible to have a combination of both remote Any function bit set to ‘‘0’’ indicates that the particular aux input is to be treated as
control and volt free inputs to provide, for example, open and close control as well a digital signal for field status reporting, e.g. a level switch or motor running status.
as a high and low tank level alarm indication, supplied via an external transducer. If the corresponding invert bit is set to a "0", an open contact is reported as a logic
‘‘1’’ and a close contact is reported as a logic ‘‘0’’ (i.e. this will invert the input).
The hexadecimal number displayed under PF can be considered as a ‘‘software
mask’’. It is this mask that tells the DeviceNet module what type of input to expect, If the corresponding invert bit is set to a ‘‘1’’, an open contact is reported as a logic
control or input signal, and what form the input will be, normally open or normally "0" and a close contact is reported as a logic ‘‘1’’ (i.e. this gives a non-inverting
closed. input).
2. Function bit set to ‘‘1’’
characters, each of which can be sub-divided into 4 binary bits. The first 4 bits
Any function bit set to ‘‘1’’ indicates that the particular aux input is to be treated as
represent the function and the second 4 represent the input source (known as
a digital command to operate the actuator.
invert). Pictorially this can be represented as:
When the corresponding invert bit is set to a "0" this represents an N.C. contact
Left side hex character Right side hex character
as being the command source, i.e. a closing contact de-energises the input and an
Aux 4 to 1 (function) AUX 4 to 1 (Invert) opening contact energises the input.
Bits 4321 4321
When the corresponding invert bit is set to a ‘‘1’’, this represents an N.O. contact
When used for remote control of the actuator bits 4 to 1 of the function character as being the command source, i.e. a closing contact energises the input and an
have been designated as follows: opening contact de-energises the input.
3. ESD Control
Bit 3 (AUX3) – Stop (Maintain) When using ESD (aux input 4), the ESD contact mode setting [A2] should be set to
open or close the valve (refer to page 36).
Bit 1 (AUX1) – Open
(When used for digital signal inputs they are simply designated as AUX 4 to AUX 1.)
4. Stop (Maintain) Control
56
PF DeviceNet Remote
For DeviceNet this is [OP] Network .
Examples Aux I/P Mask

1. The full range of remote controls is needed. Open and Close are NO and ESD Bits: 0000 1111
Aux I/P 4 3 2 1
Invert 0011 = 3 i.e. set [PF] to [F3] The displayed option will flash (stored)
2. Open and close control is required along with 2 inverted digital signal inputs.
(Note that with this setting the open and close commands will be maintained.) For DeviceNet module positioning
Aux I/P 4 3 2 1 setting [OF] (refer to page 57).
Function 0 0 1 1 =3
NO contact input.
Aux I/P 4 3 2 1
Function 1 1 0 0 =C
57
9.12 Bus System Positioning FL Bus System Valve FH Bus System Valve Fd Bus System
Control Settings Position at 0% DV Position at 100% DV Deadband Adjustment
If the system control strategy for [FL] Low Set Point Position is the position [FH] High Set Point Position is the position All positioning commands are subject to
Pakscan, Modbus, DeviceNet or to which the actuator will move if a 0% to which the actuator will move if a a deadband tolerance.
Profibus requires intermediate valve command is sent. 100% command is sent.
The deadband sets the expected
travel positioning to a "DV" (Desired
Note that the position set for [FL] will Note that the position set for [FH] will positioning accuracy of the actuator
Value - value corresponding to required
be reported to the host as 0%. The be reported to the host as 100%. The and is dependent on various factors
position), the control parameters in this
actuator display will report % open in actuator display will report % open in including, actuator output speed,
section need to be set. ‘‘Action on Loss
the range set by the limits. the range set by the limits. number of turns and valve torque. If
of Signal’’ parameters apply only to
the deadband is set too low the valve
Modbus and Profibus systems. The default setting is for 0% to be the The default setting is for 100% to be may ‘‘hunt’’ around the set point.
Limited Range Positioning is a selectable Close limit. the Open limit.
option whereby positioning limits, 0% Use the + or - key to display the
Use the + or - key to select the desired Use the + or - key to select the desired required setting:
and 100%, can be at different positions valve position for a 0% command. valve position for a 100% command.
to those used for digital Closed and [00] to [99] – 0% to 9.9% of valve
Open limit commands. Limited range stroke.
positioning can be set using the [FL]
Low Set Point Position and [FH] High Set
Point Position screens.
It should be noted that the actuator will Position: Open
Position: Closed
respond to a digital Open or Close host
command by moving the valve to the Deadband
0% DV = Valve Closed 100% DV = Valve Open 2.5%
set limits irrespective of settings made
for positioning control.
Settings for Deadband and Motion
The displayed option will flash (stored) The displayed option will flash (stored) PRESS THE KEY.
Inhibit Time affect accuracy and
indicating that it has been set. indicating that it has been set.
response time. The displayed option will flash (stored)
Press the k key to display: Press the k key to display: indicating that it has been set.
Any settings made locally at
[FH] High Set Point Position . [Fd] Deadband .
the actuator may be overwritten by Press the k key to display:
the host on startup unless the GSD [Ft] Motion Inhibit Time .
files are locked on the Profibus card.
from www.rotork.com
58
Ft Bus System FA Modbus, Profibus & FF Modbus, Profibus
Motion Inhibit Time (MIT) DeviceNet & DeviceNet
Action on Loss of Signal Failsafe Action
MIT sets the minimum time between Modbus, Profibus & DeviceNet modules Modbus, Profibus & DeviceNet failsafe
successive position commands being can be set to respond on loss of host action when [FA] is enabled.
actioned. It is used in situations to communication by positioning the
Use the + or - key to display the
reduce the number of starts per hour valve. Modbus checks for a loss of
required setting:
and to smooth out fluctuations if general highway communications
continuous positioning is implemented. whereas Profibus & DeviceNet check [Lo] Go to Low SP position.
for a loss of communications addressed
Setting the longest possible time while
specifically to themselves. [SP] Stay put
maintaining acceptable control will
maximise the life of the motorised The default setting is off [OF] and the [HI] Go to High SP position.
valve. default timeout is 255 sec.
Use the + or - key to display the Use the + or - key to display the
required setting: required setting:
[00] to [99] = 0 to 99 seconds. [On] Failsafe as determined by setting [FF] Failsafe Action
[OF] Go to Low SP position. Go to Low SP
PRESS THE KEY.

Motion Inhibit
Time: 05 seconds The displayed option will flash (stored)
Loss of Signal
Failsafe
Failsafe Action Enabled

PRESS THE KEY.
The displayed option will flash (stored) PRESS THE KEY.
Press the k key to display: indicating that it has been set.
[FA] Loss of Signal
(Modbus, Profibus & Devicenet only).
[FF] Failsafe Action .
59
9.13 Option OJ Interrupter Timer Jd Interrupter Timer JC Position in Valve
Interrupter Timer Enabled/Disabled Direction Closing Stroke for
Timer to Start
Setting instructions for actuator When fitted, the timer will be The default for timer direction is [CL], Using the + or - key select the position
including an interrupter timer. made available for operation. timer operation will start in closing for the TIMER TO START WHEN THE
and stop in opening – pulsing VALVE IS CLOSING.
The interrupter timer enables pulsed The Interrupter cannot be operation around the close position.
“stop/start” operation by the actuator [ ] [ ] Closed = valve closed
enabled or disabled using the If pulsing operation is required to stop
as a response to local and remote [00] to [99] = percentage open
Setting Tool. in closing and start in opening – around
control commands. [ ] Open = valve open
the open position, use the + or - key.
This effectively increases the valve
The display will change to [OP] Opening .
stroke time and can be adjusted to
prevent hydraulic shock (water hammer) PRESS THE KEY.
and flow surges in pipelines.
Int. Timer Int. Timer The displayed option will flash (stored) Timer Start
The interrupter timer is an optional Disabled Enabled indicating that it has been set. Position: 25%
extra – check wiring diagram for
inclusion. Interrupter Timer Interrupter Timer Timer Set to Start Pulsing when
Disabled Enabled Closing Valve Reaches 25% Open
When the timer option is available an Timer Start PRESS THE KEY.
additional series of settings can be Closing
accessed by pressing the m key. The displayed option will flash (stored)
NOTE: If the timer option is not Pulsed Operation Around the
available pressing the m key will not Closed Position If the timing is not required in the
access setting. closing stroke select [JC] to [ ] [ ] valve
NOTE: Instructions [JC] and [JO] are closed position.
Press the m key to display interrupter for timer operation around the Closed
timer set-up screens. Press the k key to display:
position. For timing around the Open [JO] Timer Stop Position .
position, read stop for start [JC] and
start for stop [JO].
[JC] Timer Start Position .
60
JO Position in Valve Opening Jn Contactor On Time JF Contactor Off Time JE ESD Override
Stroke for Timer to Stop Interrupter Timer
Using the + or - key select the position Using the + or - key select the actuator Using the + or - key select the actuator The interrupter timer may be overridden
for the TIMER TO STOP WHEN THE run period in the range 1–99 seconds. stop period in the range 1–99 seconds. when the actuator is under ESD signal
VALVE IS OPENING. command. This will mean the actuator
will run to limit without “stop/start”
[ ] [ ] Closed = valve closed action under ESD command.
Refer to [A1] – [A3] (refer to page 36
[ ] Open = valve open Timer On Time Timer Off Time for ESD settings).
05 Seconds 25 Seconds The default for ESD override interrupter
timer is [OF] No . The interrupter timer
Actuator Run Period Actuator OFF Period
will continue “stop/start” action during
Set for 5 Seconds Set for 25 Seconds
Timer Stop ESD action.
Position: 25% PRESS THE KEY. PRESS THE KEY. If ESD must override the timer use the
+ or - to display [On] Yes .
Timer Set to Stop Pulsing indicating that it has been set. indicating that it has been set.
when Opening Valve
Reaches 25% Open Press the k key to display: Press the k key to display:
[JF] Timer Off Time . [JE] Timer Override ESD
PRESS THE KEY. (refer to note on Page 61).
Timer Override
The displayed option will flash (stored) ESD: No
ESD Override Timer OFF
If timing is not required in the opening
stroke select [JO] to [ ] [ ]. PRESS THE KEY.
Press the k key to display: The displayed option will flash (stored)
[Jn] Timer On Time . indicating that it has been set.
61
Example 9.14 Setting Tool 9.15 Inhibit Operation
Local Control [Or] After Power Loss [OS]
An actuator fitted with the interrupter The default setting for Setting Tool When protection is enabled, on power
timer and set as the example shown in Local Control is [OF] Control Disabled . The default setting for this up if a low battery is detected, the
these instructions would operate at: protection option is disabled [OF]. actuator will inhibit electrical operation
To enable Setting Tool Control press the When disabled it is important
+ or - key to select [On]. and display Power Loss Inhibit via
Rated speed from full Open to 25% that the actuator is not manually actuator alarm display (refer to page 5)
Open. operated during a power failure
PRESS THE KEY. and the monitor relay will de-energise.
1/6 if the battery is low as changes in Limits must reset and the battery
rated speed from 25% Open to Fully
The displayed option will flash (stored) position cannot be tracked - refer replaced – refer to page 66.
Closed and from Fully Closed to 25%
indicating that it has been set. to page 6 for battery level status
Open.
display. Should this occur the
With the red control selector in Local, Press the k key to display:
Rated speed from 25% Open to Fully limits must be reset before electric
the Setting Tool control keys are active [OH] Close Colour .
Open. operation takes place- refer to LC/
(refer to page 17). LO page 27. Locking the hand auto
lever can prevent manual operation
- refer to Section 3.1, page 3.
Note
I-R Tool Control
On
With a Folomatic option fitted and
the Interrupter Timer enabled, the Local Setting Tool Control Enabled Power Loss
Folomatic Motion Inhibit Timer must Inhibit : Off
be adjusted to the same time as that Vandal resistant actuators ONLY
set for the Interrupter Timer “contactor (red/black selectors not supplied). The protection may be enabled by using
off”. For control, the selection of [Or] Vandal the + or - key to select [On]
Failure to do so will cause the actuator Resist is as follows:
response to defer to the lower time
PRESS THE KEY.
[On] Local Only .
which may cause control or process The displayed option will flash (stored)
problems. [OF] Control Disabled . indicating that it has been set.
For “ON” and “OFF” times in excess of [rE] Remote Only .
99 seconds apply to Rotork.
62
9.16 Indicator LEDs OH Close LED Colour OU Mid-Travel LED 9.17 Display Language
The colour of the LEDs on the IQ display The default close limit position indicator The default for mid travel position
are user configurable. These menu colour is [gr] Green . indicator colour is [OF] Off . UL
sceens allow you to set the Close LED Language
If red indication is required at the close If mid-travel LED indication is required,
colour and the Mid-Travel LED being
limit position, press the + or - key. press the + or - key.
on or off. The default display text language is
The display will change to [rE] Red . The display will change to [On] On . English. If the language was specified
at time of order the actuator will be
PRESS THE KEY. PRESS THE KEY. despatched with the specified language
The displayed option will flash (stored) The displayed option will flash (stored) set.
indicating that it has been set indicating that it has been set.
Press the + or - keys to view alternative
languages.
Available standard languages:
German Deutsch
Close Colour Mid-Travel LED
Green Off French Français
Spanish Español
Press the k key to display: Press the k key to display: Depending on the specified language,
[OU] Mid-Travel LED . [UL] Language . only English and one other may be
supplied with the actuator.
Language
English
63
[d1] and [d2]
All IQ functions are configured to a set of Rotork default (standard) settings before Rotork standard [d1] Default settings for IQ:
despatch, see the table opposite. When requested, alternative settings specified
with the order will be used. When site commissioning takes place, entered settings Function [d1] Default Setting
overwrite Rotork defaults and these ‘‘current’’ settings are used for operation along [P?] Password Unaffected – will remain as set
with the remaining unadjusted defaults. [Ir] IrDA – Insight [On] IrDA Enabled
Should difficulty be encountered during commissioning the default settings can be
reinstated, returning the actuator configuration to its original manufactured state. Basic Settings
Site commissioning must then begin again. [C1] Close Direction [C] Clockwise
There are two levels of default: [C2] Close Action [Cl] Close on Limit
d1 Rotork standard or customer specified Basic and Configuration Settings. [C3] Open Action [Cl] Open on Limit
[tC] Close Torque [40] 40% of rated
d2 Limit positions only – factory set limits.
[tO] Open Torque [40] 40% of rated
NOTE: Settings associated with control options Folomatic, Pakscan, Modbus
Profibus and Foundation Fieldbus are not affected by d1 or d2. Configuration Settings
Functions will remain as set. [r1] Indication Contact S1 [CI]/[nO] Close, Normally Open
If d1 is entered, all Basic and Configuration Settings except limit positions [r2] Indication Contact S2 [OP]/[nO] Open, Normally Open
will return to their default setting. See the table opposite for Rotork
[r3] Indication Contact S3 [CI]/[nC] Close, Normally Closed
standard settings. Basic settings (except limits) and Configuration Settings
must then be checked and reset as required (refer to Basic Settings page 22 [r4] Indication Contact S4 [OP]/[nO] Open, Normally Closed
and Configuration Settings page 31). [A1] ESD Action [SP] Stay put on ESD
If d2 is entered the limits will be reset, with the actuator positioned at 50%. [A2] ESD Contact Type [nO] Normally Open (make for ESD)
Limits must then be reset to the suit the valve (refer to Basic Settings page 20).
[A3] ESD Thermostat Override [OF] Thermostats Active during ESD
[A4] ESD Override Interlocks [OF] Interlocks Active during ESD
[A5] ESD Override Local Stop [OF] Local Stop Active during ESD
[A6] Maintained Local Control [On] Maintains in Local Control
64
[d1] and [d2] cont.
Rotork standard [d1] Default settings continued: The Rotork standard default settings are subject to change without notice.
If specified with order, [d1] settings will be configured as requested.
Function [d1] Default Setting
To reinstate [d1] settings, with [d1] displayed.
[A7] 2-wire Remote Control [SP] Stay Put on 2-wire signal
[A8] Interlocks [OF] I/L function disabled PRESS THE KEY.
[A9] Conditional Control [OF] Function disabled
The setting bars will flash, indicating the [d1] default settings have been reinstated.
[AE] Torque Switch Bypass [OF] Function disabled
[OE] Option Extra Indication Contacts [OF] Unless fitted. See wiring diagram To reinstate factory set limits (actuator positioned at 50%) with [d2] displayed,
[OI] Option CPT [HI] 4mA at Closed PRESS THE KEY.
[Od] Remote Source [rE] Unless option fitted
(refer to 9.7 page 44.) The setting bars will flash, indicating the [d2] default limits have been reinstated.
[OJ] Option Interrupter Timer [OF] Unless fitted. See wiring diagram Limits must now be reset. Refer to page 29.
[Or] Setting Tool Local Control [OF] Setting Tool Control disabled
[OS] Power Loss Inhibit [OF] Protection off
Option Extra Indication Contacts (when fitted) - refer to wiring diagram

[r5] Indication Contact S5 [CI]/[nO] Close, normally open Restore Config Reset Limits to
Range 25 Turns
[r6] Indication Contact S6 [OP]/[nO] Open, normally open
[r7] Indication Contact S7 [tI]/[nO] Torque Trip Mid Travel,
normally open [d1] Displayed [d2] Displayed
[r8] Indication Contact S8 [rE]/[nO] Remote Selected,
normally open
65
and Troubleshooting
Maintenance Routine maintenance should include WARNING: Battery Replacement
Every Rotork actuator has been fully the following: If the actuator is located within a
The battery holder in the actuator
tested before dispatch to give years of hazardous area permission must be
* Check actuator to valve fixing bolts gearcase also protects the user from
trouble-free operation providing it is obtained in the form of a ‘‘hot work
for tightness. the hazardous live connections
installed, sealed and commissioned in permit’’ or other local regulation before
accordance with the instructions given * Ensure valve stems and drive nuts are inside the actuator and therefore it removal and/or replacement of the
in this publication. clean and properly lubricated. must not be damaged. The actuator battery.
must be isolated or disconnected
The IQ actuator’s unique double sealed, * If the motorised valve is rarely Removal of the battery with the main
non-intrusive enclosure provides operated, a routine operating if the battery holder has to electrical power switched off will result
complete protection for the actuator schedule should be set up. be removed from the actuator in stored Datalogger records time
components. gearcase. reference being lost for the duration
* Replace actuator battery every
A unique circuit has been incorporated when there is no mains and battery
Covers should not be removed for 5 years.
into the battery function of the IQ, power. It is therefore recommended
routine inspection as this may be
* Check the actuator enclosure for effectively reducing the overall drain that the battery is replaced with the
detrimental to the future reliability of
damage, loose or missing fasteners. and significantly increasing the battery main electrical supply to the actuator
the actuator.
life. switched on.
* Ensure there is not an excessive
The electrical control module cover is
build up of dust or contaminant If main electrical power is not available
bonded by the Rotork quality control In normal circumstances
on the actuator. or if main power has been switched off
seal. It should not be removed as the battery replacement interval should while the battery was discharged, it is
module contains no site-serviceable * Check for any loss of lubricant. not exceed 5 years. Ambient recommended that the actuator limits
components. temperature and plant operating be checked after battery replacement
All electrical power supplies to the
The Actuator Battery conditions may affect battery life. (refer to Section 8 Commissioning Basic
The battery supports the actuator Settings, page 22).
actuator must be isolated before any Battery level status is indicated by an
position updating circuits and the
maintenance or inspection is carried icon on the actuator display, refer to
position (LCD) display when the main Battery Removal
out, except replacement of the battery. Section 3.4 Alarm Indication (refer to
power supply is turned off. It ensures The actuator must be selected to Stop
Electrical supplies must be isolated the current position is updated and page 5).
using the red selector (refer to page 3).
before actuator covers are removed displayed when manual operation takes If the battery icon is displayed the Access to the battery is via a labelled
refer to Battery replacement place with the main power turned off. battery must be replaced. sealing plug situated on the main
instructions. gearcase near the handwheel hub.
The battery is not required to retain any
actuator settings.
66
Use an 8mm Allen key to remove the If in doubt regarding the correct battery Torque and Position Monitoring
sealing plug, ensuring the ‘‘O’’ ring seal type, contact Rotork. The IQ range of actuators incorporate
remains on the plug. Disconnect the real time, instantaneous Torque &
battery wiring loom from the battery Fitting Replacement Battery Position monitoring as standard.
terminals. Using the black pull strap, lift Fit the pull strap around the
the battery out of the rubber sealing replacement battery and insert into Torque & Position can be used to
pocket. the rubber sealing pocket. Reconnect monitor valve performance during Torque = 19%
the battery wiring loom to the battery operation. The effect of process
terminals. Refit the battery sealing plug changes (differential pressure etc.) can
ensuring ‘‘O’’ ring is in good condition be evaluated. Tight spots in valve travel
and correctly fitted. Hand tighten can be pinpointed as well as gauging Example shows 19% (of rated) torque
sealing plug using an 8mm Allen key. torque developed through stroke for at 50% open position. Display torque
torque value setting (refer to pages range: [00] to [99]% of rated torque
Oil 27, 28). in 1% increments. For values of torque
Unless specially ordered for extreme Using the Setting Tool, the display can above 99% the display will indicate [HI].
climatic conditions, Rotork actuators be set to indicate Torque and Position Display position range:
are dispatched with gearcases filled as follows:
with SAE 80EP oil which is suitable for [ ] [ ] = valve closed
Fig. 10.1 ambient temperatures ranging from With the actuator displaying Current
–22°F / –30°C to 160°F / 70°C. Position, using the Setting Tool,
Battery Types [ ] = valve open
For European hazardous area certified IQ actuators do not require regular PRESS THE m KEY.
For a stationary actuator the display
actuators (ATEX) use an Ultralife U9VL oil changes (refer to Weights and The lower display will show the torque will indicate the actual torque value as
lithium manganese dioxide battery only. Measures Section 11, page 78). value as a percentage and a graphical applied by the actuator.
For FM and CSA certified enclosures use representation in the form of a bar
graph. To keep the torque & position display
an Ultralife U9VL lithium manganese active press the + or - keys. The display
dioxide battery. Equivalent, UL will remain active for approximately 5
recognised, batteries may be used. minutes from the last key operation.
For watertight (WT) actuator enclosures
use an Ultralife U9VL lithium
manganese dioxide battery or any
equivalent 9V battery.
67
Torque – Reference Profile Storing a Reference Profile Enter the correct password and press Pressing the key stores the last
IQ text display models only. the key, "Password Correct” measured “reference” close-open and
The location of torque reference profile
should display briefly and the setting open-close torque profiles within the
Only visible when in Setting Mode. See [tP] screen is shown below:
bars appear. datalogger.
Section 7, page 20.
Press the k arrow key 3 times to Press the k and m keys together to
This feature allows the user to store a 50 display the [tP] screen: return to the positional display.
reference torque profile, which can be
used to plan and determine periodic m The reference profile along with current
maintenance. 50 profiles can be viewed and analysed using
Torque
Torque IQ Insight software as shown in Fig 10.2.
After commissioning has taken place
and the process is running under m Torque Profile IQ Insight is available free, visit
normal conditions, a profile of the “as P? k PC k Ir k tP Press To Set www.rotork.com
commissioned” torque measurement
over the whole stroke can be taken m
and stored in the Datalogger. The cr k Configuration Settings
stored torque reference profile can be
compared with later torque profiles m
using Rotork Insight in order to Basic Settings
determine changes in performance of
the valve and/or process over time or
under different conditions. Each actuator is supplied without a
reference profile stored. To store a
reference profile, electrically stroke the
actuator under normal process conditions.
Once the reference stroke (close to
open / open to close) is complete stop
the actuator.
Using the supplied Setting Tool, press
the m arrow key twice to display the
password screen. Refer to section 7
page 20. Fig. 10.2
68
10 Maintenance, Monitoring 10.1 Setting Tool Pro
and Troubleshooting cont. Download & Upload
Troubleshooting (Refer to Section 3.3 page 4 – The Setting Tool Pro Download & Download/Upload Menu structure
The IQ range of actuators is the world’s Actuator Display). Upload
first that can be commissioned and Setting Tool Pro includes a feature
If the display is blank the actuator
interrogated without removing electrical which allows the user to extract
battery must be replaced and the limits dL 01 dC 01
covers. Help Screen diagnostics enable and store IQ actuator configuration
of travel reset (refer to Section 10,
fast and complete fault finding to be and datalogger files within the Tool.
page 65 – The Actuator Battery). Extract Extract
carried out. Stored files can be viewed using a PC
Datalogger Configuration
running IQ Insight ©. Using This tool,
With power off, the actuator display stored configuration files can also be
is not backlit. Position indicator uploaded back to IQ actuators in order
lamp not illuminated. to replicate a setup for multiple units
With mains power on, the actuator’s (limits must be set individually).
display should be backlit (refer to
Section 3.3 page 4 – The Actuator IQ Insight is available free from
Display). www.rotork.com P? Id
N Actuator password
Check that 3 phase supply is available Using the new features
and is of the correct voltage as stated entered?
Datalogger and configuration files
on the actuator nameplate. Measure can be extracted and stored in the
voltage phase to phase across terminals Tool without entering a password. For
1, 2 and 3 of the actuator terminal uploading configuration files from Tool
bung. to actuator, the actuator’s password Y
must first be entered correctly – see
With power Off, the actuator does section 7, page 20 for details.
not display position.
With mains power off the actuator UI 01
Accessing the menus
battery supports position indication The download/upload menus are Upload
liquid crystal display only. accessed when the Setting Tool Pro Configuration
download key m is pressed. IrDA
communication is initialised, the green
LED in the tool window will flash. The
user then has 30 seconds to “connect”
to the actuator.
69
Downloading and storing IQ Downloading and storing IQ Note. IQ actuators with non text
Datalogger Files Configuration Files displays show code/symbols only.
Press the m Key Press the m Key The screen will default to Memory
The green LED visible in the setting Tool Extract Log The green LED visible in the setting Tool
Location 01. There are a total of
Extracting Data ten memory locations available for
window will start flashing. window will start flashing.
Configuration Files, which are selected
Point the Tool at the actuator Display Extracting Log screen Point the Tool at the actuator Display by pressing the + or – keys.
Once communication has been Once communication has been When the required location has been
successfully established, the Extract Note. IQ actuators with non text successfully established, the Extract selected, press the key to initiate
Datalogger screen will be displayed: displays show code/symbols only. Datalogger screen will be displayed: the extraction. The following screen will
The extraction takes approximately 35 be displayed:
seconds for a full datalogger (2 minutes
for non text displays). After a successful
extraction, the screen will revert to
Extract Log
the Extract Log screen. If during the Extract Log
downloading an error is encountered, Memory Loc: 01 Extract Config
Memory Loc: 01 Extracting Data
Extract Datalogger screen Error , wait for the screen to revert to Extract Datalogger screen
[dL 01] and try again. Extracting Configuration screen
Note. IQ actuators with non text Note. IQ actuators with non text
Note. IQ actuators with non text
displays show code/symbols only. The action of downloading the displays show code/symbols only.
displays show code/symbols only.
actuator datalogger file will
The screen will default to Memory automatically download the
PRESS THE k KEY. The extraction takes approximately 3
Location 01. There are a total of configuration file to the Tool. The following screen will be displayed: seconds. After a successful extraction,
four memory locations available for the screen will revert to the Extract
dataloggers, which are selected by configuration screen. If during the
pressing the + or – keys. downloading an error is encountered,
When the required location has been [dL Er] will be displayed along with
selected, press the key to initiate Extract Config Error, wait for 5 seconds until the screen
Memory Loc: 01 reverts to [dC 01] and try again.
the extraction. The following screen will
be displayed: Extract Configuration screen
70
Uploading a configuration File to an PRESS THE k KEY. Note. IQ actuators with non text
IQ actuator displays show code/symbols only.
The download configuration screen will
be displayed: [dC 01] The writing process take approximately
12 seconds to complete, after which
Note: Actuator must be set to PRESS THE m KEY. the screen reverts to the Uploading
Local when writing configuration
The upload configuration screen will be Configuration screen. If during the
data.
displayed: writing process an error is encountered,
Warning: After uploading a Error , wait for 5 seconds until the screen
configuration file from the tool reverts to [UC 01] and try again.
to the actuator, the actuator basic
and configuration set up will be a
duplicate of the file set up. Write Config
Memory Loc: 01
Refer to sections 8 & 9.
Open and close limit positions and Upload Configuration screen
current position are not copied
and must be set on each individual Note. IQ actuators with non text
actuator. Refer to section 8. displays show code/symbols only.
For access to the Upload Configuration Using the + or – keys, select the
screen, the actuators password must memory location where the required
first be set correctly, see section 7. configuration file is stored and press
the key, the following screen will
Press the m Key be displayed:
The green LED visible in the setting Tool
window will start flashing.
Point the Tool at the actuator Display
Once communication has been successfully Write Config
established, the download datalogger Writing Data
screen will be displayed.[dL 01]
Uploading Configuration screen
71
10.2 Help Screens H1 Factors Inhibiting
Electrical Operation
H1
With the actuator powered up and For troubleshooting, access the BATTERY LOW ON POWER UP
Local or Stop selected, eight Help following Help Screens and refer to Bar ON = Low battery detected On
Screens can be accessed using the text: Power Up.
Setting Tool (refer to Fig. 9.1 page 32
If [OS] is selected [On] (default is [OF])
Phase Position
H1 – Factors inhibiting electrical
for their location). Loss Error
operation. the actuator operation will be inhibited
With Remote selected press the m when powered up with a discharged
key on the Setting Tool twice. The Help H2 – Monitor battery level and ESD
battery (refer to [OS] page 61).
Screens will be displayed. control input.
The battery should be replaced at the
Each screen uses bars to indicate H3 – Monitor the position limit and
Local earliest opportunity (refer to page 65).
the status of a particular control or actuator power supply status. Controls
indication function. Each bar reacts to H4 – Monitor remote control inputs to Error LOCAL CONTROLS ERROR
changes in the status of its actuator the actuator. Battery Low Bar ON = Invalid Local Control
function by turning ‘‘on’’ or ‘‘off’’. on Signals Detected.
H5 – Monitor remote interlocks local Power-up
control inputs and motor For example if a Local Open and Close
thermostats. Help Screen 1 signal is detected at the same time this
would be classed as an invalid or fault
H6 – Monitor torque switch status and POSITION ERROR condition.
IR Setting Tool communication for Bar ON = Current Position Error
vandal proof applications. Present. PHASE LOSS
H7 – Monitor travel limits, centre During power up the actuator position Bar ON = Phase Lost (3 Phase
column and position limit status. processor compares the current position Actuators Only).
H8 – Monitor the actuator’s position- to that stored in the Eeprom. If there is Loss of third monitored power supply
sensing devices. a discrepancy this is shown as a current phase connected to actuator terminal 3.
position error.
H9 – Rotork use only.
Re-setting of both actuator limits
Help screen bars shown should now be carried out (refer to
are undefined and may page 29).
be ON, OFF or flashing.
72
H2 Battery Level and H3 Factors Inhibiting H4 Remote Control
ESD Control Input Electrical Operation Inputs
H2 H3 H4
LOW BATTERY
Bar ON = Battery level low.
Bar OFF = Battery OK.
ESD Clockwise Remote Remote
Active Bar ON when the battery is low but still Limit Maintain 2 Open 1
able to support the necessary actuator
functions. Anti
Low Clockwise ESD 2 Remote
Battery The battery should be replaced at the Limit Close 1
earliest possible opportunity.
Battery Inhibit Remote
Discharged ESD SIGNAL ACTIVE Close 2 ESD 1
Bar ON = ESD Signal is present.
When applied, an Emergency Shutdown Remote Remote
Help Screen 2 Help Screen 3 Open 2 Maintain 1
Signal will override any existing local
or remote control signal, causing the Help Screen 4
BATTERY DISCHARGED CLOCKWISE LIMIT
actuator to respond in the direction
Bar ON = Battery Discharged. Bar ON = Actuator has reached All remote signals designated with ‘1’
selected for ESD.
clockwise limit of travel. are standard hard wired remote inputs.
Bar ON when the battery is no longer
The ESD function will be determined
able to support actuator functions ANTI-CLOCKWISE LIMIT When a Pakscan, Profibus or
by the settings on Control Mode
under loss of power conditions. Bar ON = Actuator has reached Foundation Fieldbus card is fitted,
Configuration screens [A1] to [A5]
The battery must be replaced (refer to (refer to Section 9.3 page 36). Anti-clockwise limit. remote control inputs are designated
Section 10 page 65) and limit positions with a ‘2’.
The actuator will not respond to any INHIBIT
reset (refer to [LC] and [LO] page 29).
local or remote control while an ESD Bar ON = Actuator inhibited. REMOTE OPEN 1
signal is maintained. Bar OFF = Remote Open Signal
Possible Causes: Present.
Phase Loss (3 phase only).
Power Loss Inhibit (page 61).
Internal Failure.
continued...
73
H4 Remote Control H5 Remote Interlocks,
Inputs continued Local Control
Inputs, & T/stat
H5
REMOTE CLOSE 1 CLOSE INTERLOCK THERMOSTAT TRIPPED
Bar OFF = Remote Close Signal Bar ON = Close Interlock Active. Bar ON = Thermostat tripped.
Present. (Actuator disabled)
Local Stop The actuator motor is protected by
ESD 1 not Open
Unauthorised Close electrical operation thermostats.
Bar OFF = ESD signal present. Selected Interlock
can be prevented by interlocking
Should the motor become overheated
the actuator (Close) control with an
REMOTE MAINTAIN 1 Thermostat Close the thermostats will trip and the
Bar OFF = Remote Maintain Tripped Interlock actuator will stop. On cooling the
signal present. If external interlocks are not required thermostat will automatically reset,
Bar ON = Remote Maintain not Local Open Local not the interlock function must be selected enabling operation. See the actuator
present and/or Remote Stop not Present Selected OFF. nameplate for the motor rating.
active.
Local Close Remote REMOTE NOT SELECTED LOCAL STOP NOT SELECTED
REMOTE OPEN 2 not not Bar ON = Remote control not selected. Bar ON = Local Stop not selected.
Bar OFF = Remote Open signal Present Selected Bar OFF = Remote control selected. Bar OFF = Local stop selected.
present from BUS option pcb. Help Screen 5
LOCAL CLOSE NOT PRESENT LOCAL NOT SELECTED
REMOTE CLOSE 2 OPEN INTERLOCK Bar ON = Local Close signal not present. Bar ON = Local control not selected.
Bar OFF = Remote Close signal Bar ON = Open Interlock Active. Bar OFF = Local Close signal present. Bar OFF = Local control selected.
present from BUS option pcb. (Actutator disabled)
LOCAL OPEN NOT PRESENT
ESD 2 Unauthorised Open electrical operation Bar ON = Local Open signal not present.
Bar OFF = ESD signal present can be prevented by interlocking Bar OFF = Local Open signal present.
from BUS option pcb. the actuator (Open) control with an
REMOTE MAINTAIN 2 If external interlocks are not required
Bar OFF = Remote Maintain the interlock function must be selected
signal present from BUS option OFF.
pcb.
74
H6 Torque Switch Status & IR H7 Travel Limits, Centre
Setting Tool Comms for Column & Remote
Vandal Proof Applications Indication Outputs
H6 H7
TORQUE SWITCH TRIPPED IR OPEN SIGNAL NOT PRESENT
Bar ON = Torque switch tripped. Bar OFF = IR Open signal present.
IR Remote When the actuator generates a value IR CLOSE SIGNAL NOT PRESENT
Control not Open
Selected of torque equal to that set for Open Bar OFF = IR Close signal present. Relay 4 Limit
(when opening) or Close (when closing)
IR Local Local it will stop, protecting itself and the IR LOCAL CONTROL DISABLED
Control Controls Relay 3 Close
Disabled not Fitted
valve from damage. This feature is Bar OFF = IR Local control enabled.
known as Over Torque Protection.
To operate the actuator locally with
IR Closed Once a torque trip has occurred further the IR Setting Tool refer to the option Actuator
Signal not operation IN THE SAME DIRECTION is selection screen [Or] Section 9.14,
Relay 2 Moving
Present prevented. page 61.
IR Open Torque This ‘‘latching’’ of the event protects Relay 1
Signal not Switch [Or] must be selected to [On].
Present Tripped the actuator and valve from repeated Help Screen 7
“hammering” against the obstruction IR REMOTE CONTROL NOT
Help Screen 6 as a response to a maintained control OPEN LIMIT
SELECTED
When actuators are supplied for signal. Bar OFF = IR Remote control Bar ON = Actuator has reached
Vandal Proof applications the local To ‘‘de-latch’’ the actuator it must be selected (vandal-proof units only). open limit.
control knobs are removed to prevent reversed. When actuator is supplied without local CLOSE LIMIT
unauthorised operation.
(For actuator torque adjustment, refer controls for vandal proof applications Bar ON = Actuator has reached
The local control functions are then to [tC ] and [tO] pages 27 and 28) the option selection screen [Or] must Close limit.
carried out by using the Infra-red be set to [rE] for
Setting Tool. ACTUATOR MOVING
Remote operation (refer to Section 9.14
page 61). Bar ON = Actuator moving.
LOCAL CONTROLS NOT FITTED
Bar OFF = Local controls fitted SWITCH CONTACTS S1, S2, S3, S4
(standard). Bar ON = S contact is close circuit.
Bar ON = Local controls not fitted
(vandal proof). Bar indication is real time and reactive
(refer to Section 9.2 [r1] page 34 for
configuration of ‘‘ S’’contacts).
75
H8 Actuator Position
Sensing Devices
H8
When the motor is running, ON and
OFF bit duration should be equal.
For the two sensors, A and B, correct
Position
Sensor A
operation is indicated by the following
truth table.
Position To observe this function, select manual
Sensor B operation and turn the actuator
handwheel clockwise, starting with all
sensors OFF:
CLOCKWISE 30 Deg.
Help Screen 8
Sensor B 0 1 1 0 0
POSITION SENSOR A
Senses output rotation. Used for Sensor A 0 0 1 1 0
per output revolution. When the motor
is running, ON and OFF bit duration
should be equal.
POSITION SENSOR B
Senses output rotation. Used for
per output revolution.
76
10.3 IQ Infrared
Diagnostic and Configuration
IQ actuators include an IrDA ® (Infrared To enable communication with IQ
Data Association) interface as standard, Insight the actuator IrDA interface The use of a notebook PC
allowing non-intrusive diagnostics, must be enabled. or PDA with actuators located in
analysis and configuration. hazardous areas will be subject
The default setting for IQ IrDA is [On], to local regulations. It is the
IQ Insight software tool for PC and IQ enabling IrDA. responsibility of the user to seek
Pocket Insight for PDA (Personal Digital guidance and permission.
To disable IrDA and prevent IrDA access,
Assistant) have been developed to
use the + or – key. The display will The Rotork Setting Tool and Setting
enable the actuator configuration and
change to [OF]. Tool Pro are certified Intrinsically
onboard datalogger to be reconfigured
and analysed. A PC running IQ Insight Safe (IS) and therefore can be used
software or PDA running IQ Pocket in defined hazardous areas (refer to
Insight can be used to interrogate the PRESS THE KEY. page 17).
actuator via non-intrusive infra red IrDA The displayed option will flash (stored)
communication. Visit www.rotork.com indicating it has been set.
for information.
Alternatively, the intrinsically safe
Rotork Setting Tool Pro allows the
user to extract and store IQ actuator
configuration and datalogger files
within the Tool. Stored files can be IrDA Comms
uploaded over an IrDA –USB interface Enabled
to a PC running Rotork IQ Insight
where they can be viewed, analysed IQ Insight and IQ Pocket Insight
and stored in a safe, clean environment. software are available free of charge
Using the Setting Tool Pro, actuator set from the Rotork web site,
up can be configured on the PC, stored www.rotork.com.
in the tool, transported to the actuator A kit is available from Rotork, which
and uploaded. The tool can transfer includes an IrDA-USB adapter and
the same configuration to multiple drivers for connection to a PC. The Kit
actuators where actuator setup is the also includes IQ Insight software. PDA
same. Refer to page 68. communication is via the internal IrDA port.
77
10.4 Environmental
End user advice on disposal at end of life of the product
Subject Definition Remarks / examples Hazardous Recyclable EU Waste Code Disposal

Batteries Lithium IQ/IQT standby battery Yes Yes 16 06 06 Will require special treatment before
Alkaline Setting tool Yes Yes 16 06 04 disposal, used specialist recyclers or
Lead Acid Battery Failsafe Units Yes Yes 16 06 01 waste disposal companies

Electrical & Printed circuit boards All Products Yes Yes 20 01 35 Use specialist recyclers
Electronic Wire All Products Yes Yes 17 04 10
Equipment
Glass Lens/Window Cenelec Qualified IQ/IQT. A Range Prism No Yes 16 01 20 Use specialist recyclers

Metals Aluminium Gearcases and covers most products No Yes 17 04 02 Use licensed recyclers
Copper/Brass Wire, IQ columns (not all sizes), motor windings No Yes 17 04 01
Zinc IQ clutch Ring and associated components No Yes 17 04 04
Iron/Steel Gears and Gearcases (A Range and larger IQ) No Yes 17 04 05
Mixed Metals IQ motor rotors No Yes 17 04 07

Plastics Glass filled nylon Covers, IQT clutch components, electronics chassis No No 17 02 04 Disposal as general comercial waste
Unfilled Gears No Yes 17 02 03 Use specialist recyclers

Oil Mineral & Kerosene Mixed Gearbox lubrication Yes Yes 13 07 03 Will require special treatment before
Mineral Gearbox lubrication Yes Yes 13 02 04 disposal, use specialist recyclers or
Food Grade Gearbox lubrication Yes Yes 13 02 08 waste disposal companies

Rubber Seals & Orings Cover and shaft sealing Yes No 16 01 99 May require special treatment before
disposal, use specialist waste disposal
companies
In all cases check local authority regulation before disposal

78
11 Weights and Measures
Oil Actuator Size Nett Weight Oil Capacity

Unless specially ordered for extreme kg/lbs litres/pt.-US
climatic conditions, Rotork actuators
are dispatched with gearcases filled IQ10 32/70 0.3/0.63
with SAE 80EP oil suitable for ambient IQ12 32/70 0.3/0.63
temperatures ranging from –22°F/
–30°C to 160°F/70°C. IQ18 32/70 0.3/0.63
NOTE: Excludes second stage gearbox IQ20 52/115 0.8/1.7

if fitted. IQ25 52/115 0.8/1.7
Food grade lubricating oil is available as IQ35 75/165 1.1/2.3
an alternative: contact Rotork.
IQ40 200/441 7.5/15.8
IQ70 215/474 7.0/14.7
IQ90 230/507 7.0/14.7
IQ91 220/485 7.0/14.7
IQ95 230/507 7.0/14.7
79
BHD Binary, Hexadecimal and
Decimal Conversion Table
BINARY HEX DEC BINARY HEX DEC BINARY HEX DEC BINARY HEX DEC BINARY HEX DEC BINARY HEX DEC BINARY HEX DEC BINARY HEX DEC
0000 0000 00 0 0010 0000 20 32 0100 0000 40 64 0110 0000 60 96 1000 0000 80 128 1010 0000 A0 160 1100 0000 C0 192 1110 0000 E0 224
0000 0001 01 1 0010 0001 21 33 0100 0001 41 65 0110 0001 61 97 1000 0001 81 129 1010 0001 A1 161 1100 0001 C1 193 1110 0001 E1 225
0000 0010 02 2 0010 0010 22 34 0100 0010 42 66 0110 0010 62 98 1000 0010 82 130 1010 0010 A2 162 1100 0010 C2 194 1110 0010 E2 226
0000 0011 03 3 0010 0011 23 35 0100 0011 43 67 0110 0011 63 99 1000 0011 83 131 1010 0011 A3 163 1100 0011 C3 195 1110 0011 E3 227
0000 0100 04 4 0010 0100 24 36 0100 0100 44 68 0110 0100 64 100 1000 0100 84 132 1010 0100 A4 164 1100 0100 C4 196 1110 0100 E4 228
0000 0101 05 5 0010 0101 25 37 0100 0101 45 69 0110 0101 65 101 1000 0101 85 133 1010 0101 A5 165 1100 0101 C5 197 1110 0101 E5 229
0000 0110 06 6 0010 0110 26 38 0100 0110 46 70 0110 0110 66 102 1000 0110 86 134 1010 0110 A6 166 1100 0110 C6 198 1110 0110 E6 230
0000 0111 07 7 0010 0111 27 39 0100 0111 47 71 0110 0111 67 103 1000 0111 87 135 1010 0111 A7 167 1100 0111 C7 199 1110 0111 E7 231
0000 1000 08 8 0010 1000 28 40 0100 1000 48 72 0110 1000 68 104 1000 1000 88 136 1010 1000 A8 168 1100 1000 C8 200 1110 1000 E8 232
0000 1001 09 9 0010 1001 29 41 0100 1001 49 73 0110 1001 69 105 1000 1001 89 137 1010 1001 A9 169 1100 1001 C9 201 1110 1001 E9 233
0000 1010 0A 10 0010 1010 2A 42 0100 1010 4A 74 0110 1010 6A 106 1000 1010 8A 138 1010 1010 AA 170 1100 1010 CA 202 1110 1010 EA 234
0000 1011 0B 11 0010 1011 2B 43 0100 1011 4B 75 0110 1011 6B 107 1000 1011 8B 139 1010 1011 AB 171 1100 1011 CB 203 1110 1011 EB 235
0000 1100 0C 12 0010 1100 2C 44 0100 1100 4C 76 0110 1100 6C 108 1000 1100 8C 140 1010 1100 AC 172 1100 1100 CC 204 1110 1100 EC 236
0000 1101 0D 13 0010 1101 2D 45 0100 1101 4D 77 0110 1101 6D 109 1000 1101 8D 141 1010 1101 AD 173 1100 1101 CD 205 1110 1101 ED 237
0000 1110 0E 14 0010 1110 2E 46 0100 1110 4E 78 0110 1110 6E 110 1000 1110 8E 142 1010 1110 AE 174 1100 1110 CE 206 1110 1110 EE 238
0000 1111 0F 15 0010 1111 2F 47 0100 1111 4F 79 0110 1111 6F 111 1000 1111 8F 143 1010 1111 AF 175 1100 1111 CF 207 1110 1111 EF 239
0001 0000 10 16 0011 0000 30 48 0101 0000 50 80 0111 0000 70 112 1001 0000 90 144 1011 0000 B0 176 1101 0000 D0 208 1111 0000 F0 240
0001 0001 11 17 0011 0001 31 49 0101 0001 51 81 0111 0001 71 113 1001 0001 91 145 1011 0001 B1 177 1101 0001 D1 209 1111 0001 F1 241
0001 0010 12 18 0011 0010 32 50 0101 0010 52 82 0111 0010 72 114 1001 0010 92 146 1011 0010 B2 178 1101 0010 D2 210 1111 0010 F2 242
0001 0011 13 19 0011 0011 33 51 0101 0011 53 83 0111 0011 73 115 1001 0011 93 147 1011 0011 B3 179 1101 0011 D3 211 1111 0011 F3 243
0001 0100 14 20 0011 0100 34 52 0101 0100 54 84 0111 0100 74 116 1001 0100 94 148 1011 0100 B4 180 1101 0100 D4 212 1111 0100 F4 244
0001 0101 15 21 0011 0101 35 53 0101 0101 55 85 0111 0101 75 117 1001 0101 95 149 1011 0101 B5 181 1101 0101 D5 213 1111 0101 F5 245
0001 0110 16 22 0011 0110 36 54 0101 0110 56 86 0111 0110 76 118 1001 0110 96 150 1011 0110 B6 182 1101 0110 D6 214 1111 0110 F6 246
0001 0111 17 23 0011 0111 37 55 0101 0111 57 87 0111 0111 77 119 1001 0111 97 151 1011 0111 B7 183 1101 0111 D7 215 1111 0111 F7 247
0001 1000 18 24 0011 1000 38 56 0101 1000 58 88 0111 1000 78 120 1001 1000 98 152 1011 1000 B8 184 1101 1000 D8 216 1111 1000 F8 248
0001 1001 19 25 0011 1001 39 57 0101 1001 59 89 0111 1001 79 121 1001 1001 99 153 1011 1001 B9 185 1101 1001 D9 217 1111 1001 F9 249
0001 1010 1A 26 0011 1010 3A 58 0101 1010 5A 90 0111 1010 7A 122 1001 1010 9A 154 1011 1010 BA 186 1101 1010 DA 218 1111 1010 FA 250
0001 1011 1B 27 0011 1011 3B 59 0101 1011 5B 91 0111 1011 7B 123 1001 1011 9B 155 1011 1011 BB 187 1101 1011 DB 219 1111 1011 FB 251
0001 1100 1C 28 0011 1100 3C 60 0101 1100 5C 92 0111 1100 7C 124 1001 1100 9C 156 1011 1100 BC 188 1101 1100 DC 220 1111 1100 FC 252
0001 1101 1D 29 0011 1101 3D 61 0101 1101 5D 93 0111 1101 7D 125 1001 1101 9D 157 1011 1101 BD 189 1101 1101 DD 221 1111 1101 FD 253
0001 1110 1E 30 0011 1110 3E 62 0101 1110 5E 94 0111 1110 7E 126 1001 1110 9E 158 1011 1110 BE 190 1101 1110 DE 222 1111 1110 FE 254
0001 1111 1F 31 0011 1111 3F 63 0101 1111 5F 95 0111 1111 7F 127 1001 1111 9F 159 1011 1111 BF 191 1101 1111 DF 223 1111 1111 FF 255
80
12 IQ Approvals
Refer to actuator nameplate for unit specific approval details
European – Hazardous area International – Hazardous area International Non hazardous

EExd IIB T4. ATEX (94/9/EC) II 2GD IECEx. Exd IIB T4 WT: Standard watertight, BS EN 60529 :1992,
Temperature -20°C to +70°C (-4°F to +158°F). IEC60079-0 and IEC60079-1 for Exd IIB T4 IP68, 7 metres/72 hours.
*Option -30°C to +70°C (-22°F to +158°F). Temperature -20°C to +60°C (-4°F to +140°F) Temperature -30°C to +70°C (-22°F to +158°F).
*Option -40°C to +70°C (-40°F to +158°F). *Option -30°C to +60°C (-22°F to +140°F). *Option -40°C to +70°C (-40°F to +158°F).
*Option -50°C to +40°C (- 58°F to +104°F). *Option -40°C to +60°C (-40°F to +140°F). *Option -50°C to +40°C (-58°F to +104°F).
*Option -50°C to +40°C (- 58°F to +104°F).
EExd IIC T4. ATEX (94/9/EC) II 2GD
Temperature -20°C to +70°C (-4°F to +158°F). IECEx. Exd IIC T4 US – Non hazardous
*Option -30°C to +70°C (-22°F to +158°F). IEC60079-0 and IEC60079-1 for Exd IIC T4 NEMA 4, 4X and 6.
*Option -40°C to +70°C (-40°F to +158°F). Temperature -20°C to +60°C (-4°F to +140°F). Temperature -30°C to +70°C (-22°F to +158°F).
*Option -50°C to +40°C (- 58°F to +104°F). *Option -40°C to +70°C (-40°F to +158°F).
*Option -50°C to +40°C (-58°F to +104°F).
EExde IIB T4. ATEX (94/9/EC) II 2GD USA – hazardous Area
Temperature -20°C to 70°C (-4°F to +158°F). FM. Class I, Division 1, Groups C & D, Class II,
*Option -30°C to +70°C (-22°F to +158°F). Division 1, Groups E, F & G. Canada – Non hazardous
*Option -40°C to +70°C (-40°F to +158°F). Factory Mutual - Explosionproof to NEC Article 500. CSA WT: Canadian Standard Association
*Option -50°C to +40°C (-58°F to +104°F). Temperature -30°C to +60°C (-22°F to +140°F). –Watertight.
EExde IIC T4. ATEX (94/9/EC) II 2GD *Option -40°C to +60°C (-40°F to +40°F). Wiring and components complying with CSA
*Alternative for Group B hazardous area. Temperatures as for Enclosure 4 and 4X.
Groups C and D. Temperature -30°C to +70°C (-22°F to +158°F).
*Option -30°C to +70°C (-22°F to +158°F).
*Option -40°C to +70°C (-40°F to +158°F).
*Option -40°C to +70°C (-40°F to +158°F).
*Option -50°C to +40°C (-58°F to +104°F).
*Option -50°C to +40°C (- 58°F to +104°F). Canada – hazardous Area
CSA EP. Class I, Division 1, Groups C and D hazardous areas.
Canadian Standard Association - Explosionproof Rotork can supply actuators to national
Temperature -30°C to +70°C -22°F to +158°F). standards not listed above. For details please
*Option -50°C to +40°C (-58°F to +104°F). contact Rotork.
*Alternative for Group B hazardous area.
*Option -50°C to +40°C (- 58°F to +104°F).
If your Rotork actuator has been correctly Australia Canada Chile Colombia
installed and sealed, it will give years of Western Australia Agent Rotork Company HQ Agent Agent Main Office
trouble-free service. Tel: +61 8 9314 1827 Tel: +1 403 569 9455 Tel: +56 2 441 1033/699 2001 Tel: +57 1 621 27 40
Fax: +61 8 9314 1837 Fax: +1 403 569 9414 Fax: +56 2 441 1023 Fax: +57 1 621 25 61
Should you require technical assistance or E-Mail: sales@pipact.com.au E-Mail: info@rotork.ca E-Mail: valvulas@ineco.cl E-Mail: bogota@automatizacion.com.co
spares, Rotork guarantees the best service
in the world. Contact your local Rotork Austria Canada China Costa Rica
representative or the factory direct at the Agent Edmonton North/Beijing Agent
address on the nameplate, quoting the Tel: +43 7224 66008 Rotork Company Rotork Company Tel: +506 228 8630/1
actuator type and serial number. Fax: +43 7224 66008 Tel: +1 780 462 8153 Tel: +86 10 8284 5700/03 Fax: +506 289 4350
E-Mail: helmut.kilches@tor.at Fax: +1 780 462 8054 Fax: +86 10 8284 5697 E-Mail:eiomega@sol.racsa.co.cr
Algeria E-Mail: info@rotork.ca E-Mail: rotorkbj@public3.bta.net.cn
Tel: + 213 414 89854 Bahrain Croatia
Fax: + 213 414 89854 Agent Canada China Agent
E-Mail: Tel: +973 727790 Montreal Shanghai Tel: +385 1 4 577 217
Fax: +973 727811 Rotork Company Rotork Company Fax: +385 1 4 577 220
Argentina E-Mail: aeradio@batelco.com.bh Tel: +1 514 355 3003 Tel: +86 21 6478 5015 E-Mail:
Tel: +54 11 4755 5560 Fax: +1 514 355 0024 Fax: +86 21 6478 5035
Fax: +54 11 4755 5560 Belgium E-Mail: info@rotork.ca E-Mail: crouse.shen@rotork.com.cn Cyprus
E-Mail: metalart@ciudad.com.ar Agent Agent
Tel: +32 2 7263300 Canada China Tel: +357 2 434131
Australia Fax: +32 2 7263633 Sarnia Sichuan Fax: +357 2 433416
Rotork Company HQ E-Mail: info@prodim.biz Rotork Company Rotork Branch E-Mail: ltdinfo@stavrinides.com.cy
Tel: +61 3 53 381566 Tel: +1 519 337 9190 Tel: +86 28 864 86081
Fax: +61 3 53 381570 Bolivia Fax: +1 519 337 0017 Fax: +86 28 864 86082 Czech Republic
E-Mail: mail@rotork.com.au Agent E-Mail: info@rotork.ca E-Mail: rotorkcd@mail.sc.cninfo.net Agent
Tel: +591 3 532615 Tel: +420 5 48321534
Australia Fax: +591 3 552528 Canada China (South) Fax: +420 5 48216240
Brisbane E-Mail: inca@roble.entelnet.bo Toronto Guangzhou E-Mail: pokorny.office@tesnemi.cz
Rotork Company Rotork Company Rotork Branch
Tel: +61 7 5429 0391 Brazil Tel: +1 905 363 0136 Tel: +86 20 628 23266 Denmark
Fax: +61 7 5429 0392 Agent Fax: +1 905 363 0320 Fax: +86 20 628 23265 Agent
E-Mail: greg.richardson@rotork.com.au Tel: +55 71 235 6588 E-Mail: info@rotork.ca E-Mail: Tel: +45 32531777
Fax: +55 71 235 3299 rotorkgz@public.guangzhou.gd.cn Fax: +45 32530504
Australia E-Mail: bahia@fluxopet.com.br Caribbean (Puerto Rico) E-Mail:
Sydney Agent China
Rotork Company Brunei Tel: +1 787 751 4415 Hong Kong Ecuador
Tel: +61 2 9 567 2735 Agent Fax: +1 787 250 1842 Rotork Company Agent
Fax: +61 2 9 567 2739 Tel: +673 3 336122 E-Mail: Tel: +852 2520 2390 Tel: +593 2 243 0373
E-Mail: Fax: +673 3 336142 Fax: +852 2528 9746 Fax: +593 2 244 3782
E-Mail: cnets@brunet.bn E-Mail: rotorkhk@netvigator.com E-Mail: digitech1@andinanet.net
Finland India Ireland (Southern) Kuwait Mexico
Agent Calcutta Dublin Agent Agent Agent
Tel: +358 9 350 7410 Rotork Branch Tel: +353 1 416 5100 Tel: +965 241 5921 Tel: +52 5 559 2959
Fax: +358 9 374 3590 Tel: +91 33 282 3306 Fax: +353 1 416 5145 Fax: +965 241 2485 Fax: +52 5 575 1092
E-Mail: Fax: +91 33 282 3473 E-Mail: pkelly@pli.ie E-Mail: Unetcon@hotmail.com E-Mail: info@rotork.com.mx
E-Mail: rotorkcal@vsnl.com
France Italy Latvia Netherlands
Rotork Company India Rotork Company Agent Rotork Company
Tel: +33 1 43 11 15 50 Chennai Tel: +39 02 45703300 Tel: +371 7 315087 Tel: +31 10 414 6911
Fax: +33 1 48 35 42 54 Rotork Company Fax: +39 02 45703301 Fax: +371 7 315084 Fax: +31 10 414 4750
E-Mail: mail@rotork.fr Tel: +91 44 625 4219/8136 E-Mail: rotork.italia@rotork.it E-Mail: rino@mailbox.neonet.lv E-Mail: sales@rotork.nl
Fax: +91 44 625 7108
Germany E-Mail: rotork@rotork.co.in Japan Libya New Zealand
Rotork Company Osaka Agent Auckland
Tel: +49 2103 95876 India Rotork Company Tel: +218 21 481 5684 Agent North Island
Fax: +49 2103 54090 Mumbai Tel: +81 728 35 7555 Fax: +218 21 481 0731 Tel: +64 9 575 2020
E-Mail: info@rotork.de Rotork Branch Fax: +81 728 35 7548 E-Mail: Fax: +64 9 575 7020
Tel +91 22 252 04578 E-Mail: E-Mail:
Greece Fax: +91 22 252 04540 Lithuania
Agent E-Mail: rotork@boms.vsnl.net.in Japan Agent New Zealand
Tel: +30 210 653 6610 Tokyo Tel: +370 7 202410 Christchurch
Fax: +30 1 6517810 India Rotork Company HQ Fax: +370 7 207414 Agent South Island –
E-Mail: melco@tee.gr New Delhi Tel: +81 3 5632 2941 E-Mail: agava@kaunas.aiva.lt Head Office
Rotork Branch Fax: +81 3 5632 2942 Tel: +64 3 353 4665
Hungary Tel +91 11 5616305 E-Mail: mail@rotork.co.jp Malaysia Fax: +64 3 353 4666
Agent Fax: +91 11 5502840 East Malaysia E-Mail:
Tel: +36 76 495932 E-Mail: rotorkl@del3.vsnl.net.in Jordan Agent
Fax: +36 76 495936 Agent Tel: +60 85 410079 New Zealand
E-Mail: Indonesia Tel: +962 6 581 9982 Fax: +60 85 419484 Wellington
Rotork Company Fax: +962 6 582 5818 E-Mail: dacingm@po.jaring.my Agent North Island
India Tel +62 21 5806764 E-Mail: tcops@go.com.jo Tel: +64 4 477 5070
Bangalore Fax: +62 21 5812757 Malaysia Fax: +64 4 477 5049
Rotork Factory E-Mail: rotork@indosat.net.id Korea (South) Kuala Lumpur E-Mail:
Tel: +91 80 8395576 Rotork Company Rotork Company
Fax: +91 80 8391601 Ireland (Northern) Tel: +82 331 265 0962 Tel: +60 3 5192 8812 Nigeria
E-Mail: rotorkblr@vsnl.com Agent Fax: +82 331 265 1369 Fax: +60 3 5192 8821 Agent
Tel: +44 28 90 841004 E-Mail: rotork@rotork.co.kr E-Mail: rotork@rotork.com.my Tel: +234 1 4522955/523225
Fax: +44 28 90 841007 Fax: +234 1 4522887
E-Mail: flotecsales@aol.com E-Mail: cnccorp@hyperia.com
Norway Poland Saudi Arabia Thailand United States of America
Bergen Agent Rotork Company Rotork Company Rotork Company
Agent Sales Office/Workshop Tel: +48 22 723 1770 Tel: +966 3 833 1661 Tel: +66 2 272 7165-6 Duluth
Tel: +47 56 312900 Fax: +48 22 723 1780 Fax: +966 3 833 9369 Fax: +66 2 272 7167 Tel: +1 770 623 6301
Fax: +47 56 312920 E-Mail: sales@tech-eng.com.pl E-Mail: rotork@awalnet.net.sa E-Mail:mail@rotork.co.th Fax: +1 770 623 6124
E-Mail: mail@scanarmatur.no E-Mail:miguel.lopez@rotork.com
Portugal Singapore Trinidad
Norway Agent Rotork Company Agent United States of America
Oslo Tel: +351 21 486 43 25 Tel: +65 6457 1233 Tel: +1 868 6524889/6523422 Chicago & Mid West
Agent Sales Office Fax: +351 21 483 57 17 Fax: +65 6457 6011 Fax: +1 868 6522651 Rotork Company
Tel: +47 23 039081 E-Mail:Lca.Lcaeng@clix.pt email: E-Mail:trinval@tstt.net.tt Tel: +1 815 436 1710
Fax: +47 23 039090 Fax: +1 815 436 1789
E-Mail: linell@scanarmatur.no Qatar South Africa Turkey E-Mail:
Agent Rotork Company Agent
Oman Tel: +974 44 19603 Tel: +27 11 453 9741-3 Tel: +90 216 327 34 71 United States of America
Agent Fax: +974 44 19604 Fax: +27 11 453 9894 Fax: +90 216 327 34 72 Houston
Tel: +968 245 95536 E-Mail:petrotec@qatar.net.qa E-Mail: E-Mail:orhant@omasteknik.com Rotork Company
Fax: +968 245 93643 Tel: +1 713 856 5640
E-Mail: riyam@omantel.net.om Romania Spain U.K. Fax: +1 713 856 8127
Agent Rotork Company Head Office, E-Mail:
Pakistan Tel: +40 244 177 677 Tel: +34 94 676 6168 Tel: +44 1225 733200,
Agent Fax: +40 244 514 664 Fax: +34 94 676 6018 Fax +44 1225 333467 United States of America
Tel: +92 21 5861509/5861510 E-Mail:technoplus@technoplus.ro E-Mail:rotork@rotork.es E-mail: mail@rotork.co.uk North East - New York City
Fax: +92 21 5874674 Rotork Company
E-Mail: tumair@cyber.net.pk Russia Sweden United Arab Emirates Tel: +1 814 835 8349
Rotork Company Partille Agent Fax: +1 814 835 8909
Peru Tel: +7 095 937 7726 Agent Head Office Tel: +971 2 626 9970 E-Mail:
Agent Fax: +7 095 234 9125 Tel: +46 31 449 450 Fax: +971 2 626 9462
Tel: +51 1 433 5883 E-Mail: rotork.russia@mtu-net.ru Fax: +46 31 442 455 E-Mail: United States of America
Fax: +51 1 433 5883 E-Mail:alnab@alnab.se Northern California
E-Mail: informes@austina.com Saudi Arabia United States of America Rotork Company
Agent/J.V. Taiwan Rotork Company HQ Tel: +1 707 252 4679
Philippines Tel: +966 3 833 1661 Agent Rochester Fax: +1 707 252 4574
Manila Agent Fax: +966 3 833 9369 Tel: +886 2 2577-1717 Tel: +1 585 247 2304 E-Mail:
Tel: +63 2 7816624 E-Mail: rotork@concept.net.sa Fax: +886 2 2577-5588 Fax: +1 585 247 2308
Fax: +63 2 7431551 E-Mail:jerdiing@ms24.hinet.net E-Mail:info@rotork.com United States of America
E-Mail: icon@i-manila.com.ph Northwest Area
Rotork Company
Tel: +1 253 838 5500
Fax: +1 253 838 5400
E-Mail: charlie.haynes@rotork.com
United States of America Venezuela & N. Antilles
Philadelphia Puerto La Cruz
Rotork Company Rotork Company
Tel: +1 856 223 1926 Tel: +58 281 268 0759
Fax: +1 856 223 9012 Fax: +58 281 266 3554
E-Mail: bob.tomchak@rotork.com E-Mail:
United States of America Yemen

South Central Region Agent
Rotork Company Tel: +967 1 420 740
Tel: +1 972 459 4957 Fax: +967 1 420 739
Fax: +1 972 745 2041 E-Mail:ssl@y.net.ye
E-Mail: skip.kuehn@rotork.com
United States of America

Petaluma
Rotork Company
Tel: +1 707 769 4880
Fax: +1 707 769 4888
E-Mail:
Venezuela & N. Antilles

Rotork Company HQ
Tel: +58 2 212 952 0814
Fax: +58 2 212 952 1925
E-Mail: rotorkvz@cantv.net

Cagua
Rotork Company
Tel: +58 244 463 5911
Fax: +58 244 463 5911
E-Mail:

Maracaibo
Rotork Company
Tel: +58 261 579 315
Fax: +58 261 579 315
E-Mail:rotorkvgz@cantv.net
Heading
Published and produced in the U.K. by Rotork Controls Ltd.

ATTENTION: RED PLASTIC PLUGS IN CONDUIT ENTRIES ARE FOR TRANSIT ONLY.
FOR LONG TERM PROTECTION FIT SUITABLE METAL PLUGS.

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

SON UNICAMENTE PARA TRANSPORTE. PARA PROTECCION PERMANENTE
COLOCAR TAPONES METALICOS APROPIADOS.
ACHTUNG: DIE ROTEN PLASTIKSTOPFEN SIND NUR FÜR DEN TRANSPORT

GEEIGNET. FÜR DAVERHAFTEN SCHUTZ SIND DIESE GEGEN GEEIGNETE
BLINDSTOPFEN AUSZÜTAUSCHEN.
ATTENTION: LES BOUCHONS PLASTIQUES ASSURENT UNE PROTECTION

TEMPORAIRE. POUR UNE PROTECTION DEFINITIVE UTILISER DES BOUCHONS
METALLIQUES.
As we are continually developing our products,

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

Wd210-Ez610-00556_steam Turbine Operation &amp; Maintenance Manual (Part_2b)

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Titolo Identificativo Rev.

OPM VPFO PTE/TVP ENG

1 Revised where indicated

2 Revised where indicated – Final issue

Rev Scopo Preparato Controllato Verificato Verificato Approvato Data

EMPRESA ELECTRICA VENTANAS S.A.

0369 – NUEVA VENTANAS 2 2 14

STEAM TURBINE OPERATION AND MAINTENANCE MANUAL

MAV, MAX LUBE OIL, CONTROL AND PROTECTION SYSTEM

MAW GLAND SEAL SYSTEM

0369 – NUEVA VENTANAS 2 3 14

STEAM TURBINE OPERATION AND MAINTENANCE MANUAL

01 General safety prescription 608W542 B

02 Mechanical outline TXMA*M504 4

03 Heavy turbine parts outline TXMA*M510 1 !

04 MA/BU100 ST Thermal insulation drawing 254H273

05 MA/HA851 Hydraulically prestressed foundation bolts 606W561

06 Prestress values and tightening torques 606W562

07 Inspection of turboset by endoscope 606W563

08 Bolt tensioning device 606W626

09 MA/HA900 Hydraulic tightening of elongation bolts 602W620 A

10 Special tool list TXMA*M569

11 Steam turbine wiring diagrams TXMA*E531 5 !

0369 – NUEVA VENTANAS 2 4 14

STEAM TURBINE OPERATION AND MAINTENANCE MANUAL

1. MAA10 High-pressure turbine HD2O 608W582

3. MAA10CT001 Temperature sensor 612W469

4. MAA10HA/HB400 Reaction blading 606W611

6. MAA10HB400 HP - blading (rotating blades) 248W217

7. MAA10HA400 Identification drawing (stationary blades) 248T191

8. MAA10HB400 Identification drawing (rotating blades) 248T195

9. MAA10HA710 HP gland seal (exhaust end) 606W566

10. MAA10HA720 HP gland seal (inlet end) 606W603

11. MAA10HA900 Shaft lifting bar 232K223 A

12. Shrink ring burner 606W567

13. MAA11AA001 Main stop valve 606W568

14. MAA11AA001 Stop valve actuator SSA 606W651

15. MAA11AA001 SSA actuator cabling 216T175

16. MAA11AA011 Main control valve 606W574

17. MAA11AA011 Control valve actuator STAE 606W575

18. MAA11AA011 STAE actuator cabling 214T357 A

19. MAA11AA061 Check valve insert 606W576

0369 – NUEVA VENTANAS 2 5 14

STEAM TURBINE OPERATION AND MAINTENANCE MANUAL

20. MAA11CG011 Inductive displacement transducer 606W514

21. MAA11AA501 Directional control valve 606W577

22. MAA11AU031 Proportional control valve 606W579

23. MAA11AU031 Power amplifier 606W580

MAA11AU031 Inductive displacement transducer see MAA11AU031

24. MAA11BQ001 Swing arm support 606W581

MAA12AA001 Main stop valve see MAA11AA001

MAA12AA001 Stop valve actuator SSA see MAA11AA001

MAA12AA001 SSA actuator cabling see MAA11AA001

MAA12AA011 Main control valve see MAA11AA011

MAA12AA011 Control valve actuator STAE see MAA11AA011

MAA12AA011 STAE actuator cabling see MAA11AA011

MAA12AA061 Check valve insert see MAA11AA061

MAA11AU031 Inductive displacement transducer see MAA11AU031

25. MAA11BQ001 Swing arm support see MAA11BQ001

0369 – NUEVA VENTANAS 2 6 14

STEAM TURBINE OPERATION AND MAINTENANCE MANUAL

1. MAB IP Turbine 608W580

2. MAB10HA400 IP - blading (stationary blades) 248W218

8. MAB11AA001 Intercept stop and control valve 612W490

Wd210-Ez610-00556_steam Turbine Operation & Maintenance Manual (Part_2b)

Wd210-Ez610-00556_steam Turbine Operation & Maintenance Manual (Part_2b)