rotork CVL 500, CVL 1500, CVQ 1200, CVQ 2400 Installation And Maintenance Instructions Manual

Electric Actuators and Control Systems

Established Leaders in Valve Actuation

This Manual contains important safety
information. Please ensure it is thoroughly read
and understood before installing, operating or
maintaining the equipment.

CVL Range

Linear Control Valve Actuator (CVL)

Installation & Maintenance Instructions

Publication P170E Issue 04/09

2

Contents

Contents

General Information 4

Hazardous Area Approvals 5

Health & Safety 6

Storage 7

Operating your CVA Actuator 8

Installation & Setup Guide 12

Mounting the Actuator 14

Cable Connections 15

Commissioning 17

Diagnostics 45

Building on Rotork’s historical success with
innovative technology, the CVL offers a highly
accurate and responsive method of automating
control valves without the complexity and cost
of a pneumatic supply. With an increased focus
on production costs and efficiency, accurate
control of the process variable is paramount.

With resolution figures better than 0.1% and the ability to
eliminate position overshoot, the Rotork CVA range helps to
maximize product quality and plant capacity.

CVL range actuators are self contained, purpose designed
and built for continuous remote electrical operation of
control valves.

This Manual covers the Linear Control valve
Actuator Range (CVL).

Models: CVL 500 & CVL 1500

Refer to Rotork Publication P110E for full specification.

The actuator comprises:

• DC brushless electric motor.

• Reduction gearing with linear output shaft.

• Motor controller with speed, travel and thrust limitation.

• Electronic logic controls and monitoring facilities housed

in a double sealed watertight enclosure.

• Hazardous area certification meeting international and

national requirements.

All thrust and position settings as well as configuration of the
actuator are made using a non-intrusive Bluetooth
typically a PDA (not supplied).

Bluetooth
download from www.rotork.com.

™

PDA Enlight software is available for free

™

device,

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3

General Information

This manual has been produced to enable
a competent user to install, operate, adjust
and inspect the Rotork Range of Control
Valve Actuators.

The electrical installation, maintenance and use of these
actuators should be carried out in accordance with the
National Legislation and Statutory Provisions relating to
the safe use of this equipment applicable to the site of
installation.

For the UK: Electricity at Work Regulations 1989 and the
guidance given in the applicable edition of the ‘IEE Wiring
Regulations’ should be applied. Also the user should be fully
aware of their duties under the Health and Safety at Work
Act 1974.

For the USA: NFPA70, National Electrical Code

The mechanical installation should be carried out as outlined in
this manual and also in accordance with any relevant national
standard codes of practice. If the actuator nameplate indicates
that it is suitable for use in a Potentially Explosive Atmospheres
(Hazardous Areas) then the actuator is suitable for use in
Zone 1 and Zone 2 (or Div 1 and Div 2) hazardous area
classifications, as defined by the actuator’s nameplate marking.

Any equipment connected to the actuator should be of
an equivalent (or better) hazardous area certification. The
installation, maintenance and use of the actuator installed in
a hazardous area must be carried out by a competent person
and in accordance with all relevant codes of practice for the
particular Hazardous Area certification.

®

is applicable.

Any inspection or repair of Hazardous Area approved
actuators should not be undertaken unless it conforms to
National Legislation and Statutory Provisions relating to the
specific Hazardous Area. Only Rotork approved actuator
replacement parts should be used. Under no circumstances
should any modification or alteration be carried out on the
actuator, as this could invalidate the conditions under which
its certification was granted.

Access to live electrical conductors is forbidden in a Hazardous
Area unless it is done under a special permit to work,
otherwise all power should be isolated and the actuator
moved to a non-hazardous area for repair or attention.

Enclosure Materials

The enclosures on the Rotork Range of Control Valve
Actuators are manufactured from aluminium alloy with
stainless steel fasteners and a polycarbonate window. The
Local Control Knob and Manual Override Knob (when fitted)
are manufactured from a Polycarbonate/PBT plastic blend.
There is a potential electrostatic charging hazard associated
with these components and therefore they must only be
cleaned with a damp cloth.

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.

Should further information and guidance relating to the safe
use of the Rotork Control Valve Actuator Range be required,
it will be provided on request.

4

Hazardous Area Approvals

Refer to the actuator nameplate for it’s specific approval details.

The CVA is built in accordance with: -

European—Hazardous Area ATEX (94/9/EC) II 2 GD c

Ex d IIB T4 Gb, Ex t IIIC T120°C Db

EN60079-0, EN60079-1, EN13463-1,
EN13463-5 and EN61241-1
Ambient Temperature Range:

-20 °C to +60 °C (-4 °F to +140 °F)
*Option -40 °C to +60 °C (-40 °F to +140 °F)

Ex d IIC T4 Gb, Ex t IIIC T120°C Db

EN60079-0, EN60079-1, EN13463-1,
EN13463-5 and EN61241-1
Ambient Temperature Range:

-20 °C to +60 °C (-4 °F to +140 °F)
*Option -40 °C to +60 °C (-40 °F to +140 °F)

Ex de IIB T4 Gb, Ex t IIIC T120°C Db

EN60079-0, EN60079-1, EN60079-7,
EN13463-1, EN13463-5 and EN61241-1
Ambient Temperature Range:

-20 °C to +60 °C (-4 °F to +140 °F)
*Option -40 °C to +60 °C (-40 °F to +140 °F)

Ex de IIC T4 Gb, Ex t IIIC T120°C Db

EN60079-0, EN60079-1 and EN60079-7,
EN13643-1, EN13463-5 and EN61241-1
Ambient Temperature Range:

-20 °C to +60 °C (-4 °F to +140 °F)
*Option -40 °C to +60 °C (-40 °F to +140 °F)

International-Hazardous Area IECEx

Ex d IIB T4 Gb, Ex t IIIC T120°C Db

IEC60079-0, IEC60079-1 and IEC61241-1
Ambient Temperature Range:

-20 °C to +60 °C (-4 °F to +140 °F)
*Option -40 °C to +60 °C (-40 °F to +140 °F)

Ex d IIC T4 Gb, Ex t IIIC T120°C Db

IEC60079-0, IEC60079-1 and IEC61241-1
Ambient Temperature Range:

-20 °C to +60 °C (-4 °F to +140 °F)
*Option -40 °C to +60 °C (-40 °F to +140 °F)

Ex de IIB T4 Gb, Ex t IIIC T120°C Db

IEC60079-0, IEC60079-1, IEC60079-7 and IEC61241-1
Ambient Temperature Range:

-20 °C to +60 °C (-4 °F to +140 °F)
*Option -40 °C to +60 °C (-40 °F to +140 °F)

Ex de IIC T4 Gb, Ex t IIIC T120°C Db

IEC60079-0, IEC60079-1, IEC60079-7 and IEC61241-1
Ambient Temperature Range:

-20 °C to +60 °C (-4 °F to +140 °F)
*Option -40 °C to +60 °C (-40 °F to +140 °F)

USA– Hazardous Area

FM. Explosionproof, Class I, Div 1, Groups C & D, T4

Ambient Temperature Range:

-20 °C to +60 °C (-4 °F to +140 °F)
*Option -40 °C to +60 °C (-40 °F to +140 °F)

FM. Explosionproof, Class I, Div 1, Groups B, C & D, T4

Ambient Temperature Range:

-20 °C to +60 °C (-4 °F to +140 °F)
*Option -40 °C to +60 °C (-40 °F to +140 °F)

FM. Dust Ignitionproof, Class II, Div 1, Groups E, F & G, T4

Ambient Temperature Range:

-20 °C to +60 °C (-4 °F to +140 °F)
*Option -40 °C to +60 °C (-40 °F to +140 °F)

CVL Linear Actuator

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5

Health & Safety

WARNING

Before installing the actuator, make sure that it is suitable for
the intended application. If you are unsure of the suitability
of this equipment for your installation consult Rotork prior
to installation.

WARNING: ELECTRIC SHOCK HAZARD

Installation and servicing must be performed only by
qualified personnel.

WARNING: ELECTROSTATIC DISCHARGE

This equipment houses static sensitive devices. To protect the
internal components never touch the printed circuit boards
without using electrostatic (ESD) control procedures.

WARNING: ENCLOSURE MATERIALS

CVL 500 and CVL 1500 actuator castings are manufactured
from aluminium alloy with stainless steel fasteners. 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: OPERATING BY HAND

Where actuators are supplied with the optional hand­wheel, note that under no circumstances should any
additional lever device such as a wheel key or wrench
be applied to the hand-wheel in order to develop more
force when closing or opening the valve. This may cause
damage to the valve and/or actuator and it may also
cause the valve to become stuck in the seated or back
seated position.

WARNING: RESERVE POWER PACK

Where actuators are supplied with the reserve Power
Pack Assembly please note that the actuator output
shaft may move after removal of the power supply.

Move the Knob Selector to the ‘STOP’ position to
prevent any unwanted electrical movement. The CVA
actuator and in particular the power pack contain no
user serviceable components and the top cover assembly
must be removed by suitably qualified personnel only.

6

Storage

Receiving / Inspection

Carefully inspect for shipping damage. Damage to the
shipping carton is usually a good indication that it has
received rough handling. Report all damage immediately to
the freight carrier and your local CVA distributor.

Unpack the product and information packet taking care to
save the shipping carton and any packing material should
return be necessary. Verify that the items on the packing list
or bill of lading agree with your own documentation.

Storage

If your actuator cannot be installed immediately store it in a
dry place until you are ready to connect incoming cables.

If the actuator has to be installed but cannot be cabled it is
recommended that any plastic transit cable entry plugs are
replaced with PTFE sealed metal plugs.

The Rotork double sealed construction will preserve internal
electrical components perfectly if left undisturbed. It is not
necessary to remove any electrical compartment covers in
order to commission the CVL actuator.

Rotork cannot accept responsibility for deterioration caused
on-site once the covers are removed. Every Rotork actuator
has been fully tested before leaving the factory to give
years of trouble free operation providing it is correctly
commissioned, installed and sealed.

Identification Label

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7

Operating your actuator

The following instructions must be followed and integrated
with your safety program when installing and using Rotork
Controls products.

• Read and save all instructions prior to installing,

operating and servicing this product.

• If you don’t understand any of the instructions contact

Rotork for clarification.

• Follow all warnings, cautions and instructions marked on

and supplied with the product.

• Inform and educate personnel in the proper installation,

operation and maintenance of the product.

Install equipment as specified in Rotork Controls
installation instructions and as per applicable local and
national codes of practice. Only connect to electrical
power supplies having the correct voltage, current and
rating (refer to nameplate).

• To ensure proper performance, use only qualified

personnel to install, operate, update and maintain
the unit.

• When replacement parts are required, ensure that the

qualified service technician uses only replacement parts
specified by Rotork.

• Substitutions will invalidate any hazardous area

certification and may result in fire, electrical shock, other
hazards or improper operation.

• Keep all product protective covers in place (except during

installation or maintenance by qualified personnel)
to prevent electrical shock, personal injury or damage
to equipment.

• Operation of the actuator in an inappropriate fashion

may cause harm or damage to the unit or surrounding
equipment.

WARNING: OPERATING BY HAND

Where actuators are supplied with the optional hand­wheel, note that under no circumstances should any
additional lever device such as a wheel key or wrench
be applied to the hand-wheel in order to develop more
force when closing or opening the valve. This may cause
damage to the valve and/or actuator and may also
cause the valve to become stuck in the seated or back
seated position.

Where actuators are supplied with optional hand wheel device
the valve can be operated manually independent of the power
supply.

Move the Selector Knob to the STOP position before
attempting to operate the actuator manually.

Push and turn simultaneously to manually operate the actuator.

WARNING: OPERATING ELECTRICALLY

Check that the power supply voltage agrees with that on the
actuator nameplate.

Do not switch on the power supply until you have checked
that the actuator has been connected correctly.

8

Local Controls

The actuator is supplied with a 3 position selector knob
located on the top cover assembly. The knob assembly has a
locking latch to enable the control knob to be padlocked in
position. In the centre of the knob assembly is a tri state LED.
Refer to Table 1 for full details of LED indication.

The LED has 3 colour states RED, GREEN or BLUE.

The LED can be ‘ON’ or FLASHING depending on the actuator
status.

Stop

With the selector knob in the ‘STOP’ position no electrical
operation is possible.

Run

With the selector knob in the ‘RUN’ position the actuator will
respond to remote control commands. During commissioning
or diagnostic procedures using PDA or Smartphone
Bluetooth
remotely.

Note: When STOP or RUN is selected the control knob
can be rotated between the two positions without
having to depress the locking latch. It is also possible
to lock the selector in the ‘RUN’ or ‘STOP’ only position.

™

enabled devices the actuator may not be operated

Fig. 11.1

Tes t

With the selector knob in the ‘TEST’ position an auto test
routine will be initiated if the function is enabled.

This is a quick method of testing the actuators ability to
control its output independent of the external control system.
The actuator will perform a series of step and cycle routines
centred around the last demand position. No greater than
+/- 4% of last set point.

The test will measure the following parameters:

• Deadtime

• Step Response Time.

• Setting time

• Average Thrust/Torque in each direction of travel

• Full Stroke Speed

• Valve Friction

The user LED on the selector knob will fast flash for
10 seconds.

Flashing Green - All Parameters in acceptable limits

Flashing Red - One or more parameters outside of

acceptable limits.

Fig. 11.2

Fig. 11.3

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Fig. 11.4

in Valve Actuation Technology

9

Operating your actuator

LED Indication Actuator Status Mode of Operation

Solid Green - No Faults Run or Test

Note - Electrical operation
is not possible whilst the
RPP is charging.

Green - Slow Flash

- Auto Test in progress
or Reserve Power Pack (RPP)
charging (if fitted).

Green - Fast Flash
Auto Test completed successfully.

Blue - Fast Flash
Initiating

Run

Green/Blue - Alternate Flash Run or Test

No faults.

Initiating

Stop

Fault found or Stop selected.

Solid Red Run/Test/Stop
Major Fault Found.

Flashing Red Stop
Stop selected or minor fault found.

Red/Green Alternate Flash Run/Test/Stop
Power Failure and UPS active

Bluetooth™ connection

Blue - Slow Flash

Bluetooth™ Communication Active.

Bluetooth™ communication active

Red/Blue - Alternate Fast Flash

Bluetooth™ connection

Red/Blue - Alternate Slow Flash

Bluetooth™ communication active

Note: Slow Flash = 0.5Hz
Fast Flash = 1.0Hz

10

Table 1

RESERVE POWER PACK - (OPTIONAL)

The actuator can be fitted with an optional ‘Reserve Power
Pack’ consisting of Super Capacitors to allow the actuator to
go to a pre-determined position on power failure.

On power up the super capacitors require a charging period
during which time the actuator electrical operation will be
inhibited. This could take up to two minutes.

NOTE: Electrical operation is inhibited and the LED will
flash during the charging period.

On loss of power supply the actuator will carry out its
designated fail-to-position function. The LED remains
illuminated until the energy stored in the capacitors has
depleted.

WARNING

Where actuators are supplied with the reserve Power
Pack Assembly please note that the actuator output shaft
may move after removal of the power supply. Move
the Knob Selector to the ‘STOP’ position to prevent any
unwanted electrical movement before carrying out any
maintenance or removal of the unit from the valve.

After disconnection of the actuator power supply wait
until the LED indicator on the top cover assembly has
extinguished before attempting to remove the actuator
from the valve. Under no circumstances attempt to
remove the actuator or adjust the output drive shaft
connection to the valve stem whilst the top cover LED
is illuminated.

The CVA main housing of the actuator and in particular
the power pack contain no user serviceable components
and the top cover assembly must be removed by suitably
qualified personnel only.

DO NOT REMOVE ANY COVER ASSEMBLY TO GAIN
ACCESS TO THE ELECTRICAL COMPARTMENTS WHILST THE
LED LOCATED ON THE SELECTOR KNOB IS ILLUMINATED.

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Installation & Setup Guide

Commissioning

The Rotork CVA Range of actuators provide simple, safe
and rapid non-intrusive commissioning using a Bluetooth
enabled PDA. Actuator limit setting can be achieved using
the automatic setup feature.

Tools & Equipment Required

BluetoothTM enabled hand held computer (PDA) or
Smartphone (screen resolution 240 x 320 minimum) running
Windows

Note: Local operation is only possible with a PDA or
Smartphone. Alternatively if the HART option card is
fitted a Hart communicator can be used.

Software

The Rotork Enlight CVA software must be installed
on the PDA or Smartphone before carrying out any
commissioning procedures. The software is free issue
and is available for download from the Rotork website
at www.rotork.com.

It is essential that the setup procedure is carried
out when the valve is not under working process
conditions, as full valve movement will occur. If
actuators are fitted with a failsafe capacitor pack
the unit may operate the valve on removal of the
power supply. To prevent this occurrence, it will be
necessary to re-configure the failsafe action, see
Page 39. Alternatively ‘STOP’ can be selected to
prevent unwanted movement.

TM

Mobile operating system.

CAUTION

IMPORTANT

It is essential that the actuator is mounted correctly to
the valve.

The height of the yoke or pillar and mounting plate, in relation
to the top of the valve spindle is critical to ensure full stroke
movement of the valve. Refer to Rotork publication P110E for
further details.

The Installation & Setup will include the following procedures:

1. Ensure valve is closed and safe (Offline).

2. Actuator output shaft is retracted.
(May be necessary to apply power).

3. Mount and align actuator to valve.

4. Use the PDA to set limits of travel.

5. Use the PDA to configure control and
indication parameters.

12

Quick Setup Flow Chart

Align Coupling

Actuator not

fitted

Establish

communication

with actuator

Select Actuator

From list

Yes

Login

Select ‘User’

Password ‘sulis’

Stroke Setup

Quick Setup

Wizard

No

Work Offline

Manual Setup

Valve Actions

Set Output Thrust

and End of Travel

Options

Align Coupling

&

Fit Actuator

Input/Output

Setup

Set Demand

& Feedback

Parameters

Auto Setup

Fail Modes

Set Loss of Power

& Signal Failure

Modes

Advanced 1

Set back off &

Indication Relay

Functions

Manually set

limits of travel

Advanced 2

Set Bumpless

Transfer Functions

Characterisation

Modify Actuator

Response against

Demand profile

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13

Installation & Setup Guide

Mounting the Actuator

Move valve stem to the closed position

To enable the actuator to be installed correctly the valve must
be in the closed position to allow fitting of the valve stem/
actuator coupling.

Actuator Output Shaft

The actuator is supplied with the output shaft in the fully
retracted position. If the output shaft is in the extended
position it may be necessary to apply a temporary power
supply or manually operate the actuator using the optional
hand-wheel to the retracted position to allow installation.

Installing Actuator

Whilst no international standard currently exists for linear
flange interfaces, we conform dimensionally to MSS SP-101
and ISO 5212 for the specific flange sizes.

Actuator to mounting flange assembly fixings must conform
to Material Specification ISO Class 8.8. Delta GZ coated
Grade A4 stainless steel fixings are recommended.

Position actuator on to the valve mounting flange.

Fit securing bolts/studs and tighten down to the required
torque.

See Table 2

Fig. 16.1

Fig. 16.2

Thread Size Torque Nm Torque Lbs/ft

5/16 UNC 12.6 Nm 9.3

M8 12.8 Nm 9.4

Table 2

Fig. 16.3

14

Fig. 16.4

Cable Connections

Move the mode selector knob on top of the required actuator
to the ‘STOP’ position. This will inhibit electrical operation.

WARNING

Ensure all power supplies are isolated before removing
actuator covers.

Check that the supply voltage agrees with that stamped on
the actuator nameplate. A fuse or circuit breaker must be
included in the wiring installation of the actuator. The switch
or circuit breaker must be installed as close as possible to
the actuator and shall be marked to indicate that it is the
disconnecting device for that particular actuator. The actuator
must be protected with an over current protection device
rated in accordance with publication No. P110E, which details
the electric motor performance data for CVA range actuators.

Earth Ground Connections

An internal earthing point is provided for water tight
applications. In addition a mandatory 6mm external earthing
stud is provided for all explosion proof applications.

Removing Terminal cover

Using an 8mm Allen key loosen the captive fixings securing
the terminal compartment cover. Do not attempt to lever
off the cover with a screwdriver as this will damage the “O”
ring seal and may damage the flamepath on a certified unit.
Remove the power terminal insulated cover and connect
temporary or site wiring in accordance with the supplied
wiring diagram.

Note: The Red Power and Control terminal protective
covers should be replaced prior to refitting of the
electrical cover assembly.

When the actuator is supplied with an Intrinsically
Safe terminal compartment, the unit is supplied with
a Red and Blue terminal cover. The Blue terminal cover
identifies the IS Circuit connections.

Covers must be fitted to maintain certification.

Fig . 17.1

Fig. 17.2

Fig. 17.5

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IS Terminal Block Fig. - 17.4

in Valve Actuation Technology

15