rotork CK Series, CK Standard, CKA Atronik, CKC Centronik Use And Installation Manual
CK Range
Safe Use and Installation Manual
Modular Design Electric Valve Actuators
2
CK Range Safe Use and Installation Manual
Table of Contents
1 Introduction 4
2 Safety 5
2.1 Standards and Directives 5
2.2 Competency 5
2.3 Commissioning 5
2.4 Warnings 5
3 Transport and Storage 6
4 Actuator Identification 7
4.1 CK Standard 7
4.2 CK A Atronik 8
4.3 CKc Centronik 9
5 Preparing the Drive Bush 10
5.1 Drive Bush - Type A Coupling: 10
5.1.1 Disassembly of bearing assembly 10
5.1.2 Reassembly of bearing assembly 10
5.2 Drive Bush - Type B Coupling: 11
5.2.1 Disassembly 11
5.2.2 Reassembly 11
6 Mounting the Actuator 12
6.1 Weights and Measures 12
6.2 Mounting the Actuator - Rising Stem Valves 13
6.2.1 Fitting the actuator and base
as a combined unit - all sizes 13
6.2.2 Fitting thrust base to valve - all sizes 13
6.3 Mounting the Actuator -
Non Rising Stem Valves - Top Mounted 13
6.4 Mounting the Actuator -
Valve with Gearbox - Side Mounted 13
6.5 Actuator Sealing 13
9 Commissioning 16
9.1 Atronik Interface 16
9.2 Centronik Interface 17
9.3 Centronik Navigation 18
9.3.1 Local Selector input 18
9.3.2 Setting Tool Input 18
9.4 Centronik Feedback 19
9.4.1 Arrow Identification 19
9.4.2 Confirmation Feedback 19
9.4.3 Torque/Limit Setting 19
9.5 Basic Mechanical Switch Mechanism Setting 20
9.5.1 Instructions 20
9.5.2 Set Position Limits 21
9.6 End of Travel Action 23
9.6.1 Atronik 23
9.6.2 DIP switch functions 23
9.6.3 Centronik 24
9.7 Digital Switch Mechanism Setting 25
9.7.1 Entering Configuration mode 25
9.7.2 Entering the User Password 25
9.7.3 Menu Navigation 26
9.8 Secondar y Function Setting 28
10 Maintenance, Monitoring and Troubleshooting 28
11 Disposal / Recycling 29
12 Environmental 29
13 Components of The Modular CK Actuator Design 30
7 Cable Connections 14
7.1 Terminal block layout 14
7.2 Earth/Ground Connections 15
7.3 Removing the plug and socket 15
7.4 Cable entr y 15
8 Operating Your Actuator 15
8.1 Operating by Hand 15
8.2 Operating Electrically 15
Keeping the World Flowing
3
1 Introduction
This manual contains important information to
prevent damage in their handling, setting and use. It
is essential to follow and observe all the points. Please
observe all National Legislation for health and safety
regulations, standards and directives applicable.
This works and the information it contains are the
property of Rotork. The information it contains shall not
be reproduced or disclosed, in whole or in part without
the prior written consent of Rotork.
Instructions included in this document are applicable for
all variants of the CK Range - including but not limited to;
CK Standard, CKr, CKa, CKra, CKc and CKrc.
This manual is produced to enable a competent user to install,
operate, adjust and inspect the CK Range of valve actuators.
These user instructions are provided subject to the following
conditions and restrictions:
This document contains information of a proprietary nature
belonging to Rotork. Such information is supplied solely
for the purpose of assisting users of the CK Range of valve
actuators in its installation and maintenance.
The text and the graphics included in this document are
for the purpose of illustration and reference only. The
specifications on which they are based are subject to change
without notice.
Information in this document is subject to change without
notice.
This manual provides instruction on:
• Manual and electrical operation
• Preparation and installation of the actuator onto the valve
• Basic commissioning
• Maintenance
Refer to Publication PUB111-008 for repair, overhaul and
spare part instructions.
4
CK Range Safe Use and Installation Manual
2 Safety
All users working with this product must be familiar with
and observe the safety and warning instructions given in
this manual. To avoid personal injury or property damage
safety instructions and warning signs on the product must be
observed.
Due consideration of additional hazards should be taken
when using the product with other equipment. Further
information and guidance relating to the safe use of the
product is provided on request.
These instructions must be observed otherwise safe use and
operation cannot be guaranteed.
2.1 Standards and Directives
Rotork products are designed and manufactured in
compliance with internationally recognised standards and
directives. EC Declaration of Conformity and Incorporation are
available on request. It is the responsibility of the end user or
contractor to ensure that the legal requirements, directives,
guidelines, national regulations and recommendations
applicable to the site of installation are met with respect to
assembly, electrical connections and operation.
2.2 Competency
The user and those persons working on the equipment should
be familiar with and observe their responsibilities under any
statutory provisions relating to occupational health and safety
regulations. Before working on this product users should have
thoroughly read and understood these instructions.
Only persons competent by virtue of their training and
experience should install, maintain and repair Rotork
actuators.
2.3 Commissioning
It is important to check that all settings meet the requirements
of the application before commissioning the product. Incorrect
settings might cause damage to valves or other property.
Rotork will not be held liable for any consequential damage.
2.4 Warnings
This information is needed to avoid a safety hazard,
which might cause bodily injury
This information is necessary to prevent damage to
the product or other equipment
WARNING: Motor Thermostat / Motor Temperature
Under normal operation the surface temperature of the
actuator’s motor cover can exceed 60 °C above ambient.
Failure to correctly connect the thermostat may lead to
electrical hazards and invalidate the electrical safety case
and any safety approvals. Surface temperatures of motor
enclosures may reach temperatures which can cause
discomfort or injury to personnel accidentally coming
into contact with hot surfaces. Protection should be
provided by the user to protect against accidental contact
with hot surfaces. Failure to observe this precaution
could result in bodily injury.
WARNING: Surface Temperature
The installer/user must ensure that the actuator’s surface
temperature rating is not influenced by external heating/
cooling effect (e.g. valve/pipeline process temperatures).
CAUTION: Enclosure Materials
The CK Range of valve actuators are manufactured
from aluminum alloy with stainless steel fasteners.
The thrust bases are manufactured in SG iron. The user
must ensure that the operating environment and any
materials surrounding the actuator cannot lead to a
reduction in the safe use of, or the protection afforded
by, the actuator. Where appropriate the user must ensure
the actuator is suitably protected against its operating
environment.
WARNING: Unexpected Start up
Actuator may start and operate at any time when power
is applied. This will be dependent on remote control
signal status and actuator configuration.
WARNING: Unit Weight
The actuator weight is shown on the nameplate.
Care must be taken to transport, move or lift the actuator
safely. Lifting information is available in section 6.
Keeping the World Flowing
5
3 Transport and Storage
During transportation, care should be taken to ensure that
your actuator is protected from impact. In the unfortunate
event of your actuator receiving an impact, the actuator
should be inspected by a Rotork trained technician (for
transportation purposes, handwheels are supplied separately).
If your actuator cannot be installed immediately, store it in a
clean, dry ventilated location that is off the floor and protect it
from dust and dirt.
CK Range valve actuators are supplied with temporary plastic
transit cable entry plugs. These are for short term use and if
the unit is likely to be stored for a period of time, these must
be replaced with metal plugs which have been sealed with
PTFE tape.
If the actuator has to be installed but cannot be cabled, it is
recommended that the plastic transit cable entry plugs are
replaced with metal plugs which are sealed with PTFE tape
until you are ready to connect the incoming cables.
The CK plug and socket assembly will preserve internal
electrical components perfectly if left undisturbed. Rotork
cannot accept responsibility for deterioration caused on-site
once the covers are removed. Every CK Range actuator is fully
tested before leaving the factory to give years of trouble free
operation, providing it is correctly commissioned, installed and
sealed. Technical documentation that is supplied with each
unit must be kept safe for future reference.
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CK Range Safe Use and Installation Manual
4 Actuator Identification
4.1 CK Standard
Hand Wheel
Conduit Entries
Switch Mechanism Cover
Protective Earth Connection
(M6x1p x 10 Deep)
Plug and socket housing
Motor
Name Plate
Electric Actuator Nameplate
The actuator name plate will enable you to identify your unit.
Example below:
www.rotork.com
2
4
6
8
13
14
10
15
12
11
Hand / Auto lever
Mark Description
1 Facility Address
2 Actuator Model
3 Serial Number
4 Maximum Torque
1
3
5
7
9
5 Minimum Torque
6 Output Speed (RPM)
7 Lubricant
8 Temperature Range
9 Manufacturing Date
10 Enclosure Rating
11 Unit Barcode (Factory Use)
12 QR Code
13 Flange Size
14 Maximum Unit Weight
15 Spare Line (Tag Information)
Keeping the World Flowing
7
4 Actuator Identification
4.2 CKa Atronik
Atronik Name Plate
Conduit Entries
Protective Earth Connection
(M6x1p x 10 Deep)
Plug and socket housing
Atronik Interface
Hand Wheel
Atronik Module Nameplate
The Atronik name plate will enable you to identify your unit.
Example below:
13
Supplied and Tested by Rotork
1
2
3
4
5
6
7
8
9
Model
Serial nº
Power supply
Cust. supply
Bkp supply
P max. kW
Wiring diag.
Internal diag.
Temp. range
10
14
: ATRONIK
: S0000000102
: 3~380V/50Hz
: 24VDC/5W
: --
: 3,5
: K00000000
: D0000000
: -30ºC/+70ºC
: 06.2018Year
IP 68
Pol.Ind.110, 20100 (Spain)
11
12
Switch Mechanism Cover
Motor
Hand / Auto lever
Mark Description
1 Model
2 Serial Number
3 Power Supply
4 Customer Supply
5 Backup Supply
6 P max
7 Wiring Diagram
8 Internal Diagram
9 Temperature Range
10 Manufacturing Year
11 Serial No. Code Bar
12 QR Code
13 IP Degree
14 Address
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CK Range Safe Use and Installation Manual
4 Actuator Identification
4.3 CKc Centronik
Centronik Name Plate
Conduit Entries
Protective Earth Connection
(M6x1p x 10 Deep)
Plug and socket housing
Centronik Interface
Hand Wheel
Centronik Module Nameplate
The Centronik name plate will enable you to identify your unit.
Example below:
1
2
3
4
5
6
7
8
9
10
15
16
11
12
13
14
Switch Mechanism Cover
Motor
Hand / Auto lever
Mark Description
1 Model
2 Serial Number
3 Main Power Supply
4 Remote Control Supply
5 Internal Customer Supply
6 Backup Supply
7 Maximum Power Rating
8 Customer Wiring Diagram
9 Internal Unit Diagram
10 Temperature Range
11 Enclosure Rating
12 Manufacturing Date
13 Unit Barcode (Factory Use)
14 QR Code
15 Capacitor Value (1ph only)
16 Spare Line (Tag Information)
Keeping the World Flowing
9
5 Preparing the Drive Bush
5.1 Drive Bush - Type A Coupling:
Please see Publication PUB111-001 for thrust/torque
allowances.
(Note: CK30/60 actuators may be fitted with a F07/FA07
flange adaptor, in which case this will need to be removed
before the below procedure is carried out).
Turn the actuator onto its side, removing the hex head screws
holding the thrust base (1) onto the actuator.
Remove the two M3 cap screws retaining the spigot ring (2)
Pull out the drive bush (3) complete with the bearing
assembly (4)
1
5
6
CAUTION: Failure to remove the bearing assembly
and the o-rings prior to machining may result in damage
to the bearing.
5.1.1 Disassembly of bearing assembly
Locate and remove the snap ring (5) using a suitable tool
Remove the split collar (6)
If fitted, remove the spacer ring (7)
Slide the bearing (4) off the drive bush (3)
Keep the bearing and the drive bush components clean.
The split collar keys (6) must be kept as a machined pair.
Machine the drive bush, after removing the o-rings, allowing
clearance for rising spindle applications.
5.1. 2 Reassembly of bearing assembly
Ensure the drive bush (3) is clean and free from swarf. Ensure
the o-rings are clean and greased (see Section 11 for typical
grease). Slide the bearing assembly (4) onto the drive bush (3)
and ensure that it is fitted down to the shoulder. Grease and
refit the split collar keys (6) and spacer ring (7) if fitted and
secure with the snap ring (5).
Grease and refit the drive bush bearing assembly into the
thrust base.
Refit the thrust base (1) ensuring that the drive dogs on the
bush align with the slots in the hollow center column and
secure with the hex head screws to the following torque
values: See Table A on page 13.
7
4
3
2
10
CK Range Safe Use and Installation Manual
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