rotork EH Pro Series Installation And Maintenance Instructions Manual

EH Pro 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.

PUB021-034-00
Date of issue 05/12

The Rotork Setting Tool and Setting Tool Pro allows actuator control,
indication and protection functions to be configured to suit site requirements.
In addition, the new Rotork Bluetooth
downloading of Datalogger and uploading/downloading of configuration
files. Files are transferred to and from the Bluetooth

®

Setting Tool Pro also allows

®

Setting Tool Pro via

Insight II.

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 before proceeding.

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 Pro

2

I

Rotork Setting Tool

Bluetooth® Setting Tool Pro

Rotork

3

II

This manual provides instruction on:

• Electrical(localandremote)andoptionalmanualoperation.

• Preparationandinstallationoftheactuatorontothevalve.

• SubsequentcommissioningandadjustmentoftheBasicSettings

for correct valve operation.

• CommissioningandadjustmentoftheConfigurationSettingsto
suit site-specific control and indication requirements.

• MaintenanceandTroubleshooting.

• SalesandService.

THE ROTORK FLUID SYSTEMS EH Pro RANGE – A RELIABLE
SOLUTION FOR ELECTRIC FAILSAFE AND MODULATING VALVE
CONTROL THAT YOU CAN COMMISSION AND INTERROGATE
WITHOUT REMOVING ELECTRICAL COVERS.

Using the supplied infrared / Bluetooth setting sool to access the actuator
set up procedures, non-intrusive setting of internal hydraulic pressure levels,
position limits and all other control and indication functions can be made
safely, quickly and conveniently, even in hazardous locations

Standard diagnostics information about the control system, valve and
actuator status in the form of display icons and help screens.

Setup,AlarmandstatustextisavailableinEnglish(default).
Other languages are available upon request.

Instantaneous internal hydraulic pressure and position can be monitored on
the actuator with a single key press of the Setting Tool.

The on board Datalogger captures operational and valve data enabling

informedmaintenancechoicestobemade.InsightIIsoftwareforPCallows

the Datalogger to be interrogated, as well as the complete actuator set up
to be configured and recorded.

Visitourwebsiteatwww.rotork.comformoreinformationontheEHPro,
Insight II and other Rotork actuator ranges.

TheRotorkEHPro Range of self-contained, electro-hydraulic actuators
include an integrated control module; a hydraulic manifold; and a power

unitconsistingofamotor,hydraulicpumpandreservoir.EHactuatorsare

available in double-acting or spring-return configurations for both quarter­turn and linear applications.

They can be configured to mount in any position, including remote

mountingofthecontrolmoduleand/orhydraulicpowerunit(HPU).Torque
requirementsupto600,000Nm(5.3millionlbf-in)andthrustsupto
5,500,000N(1.2millionlbs)canbeaccommodated.

All electronics are protected in a watertight or explosion-proof enclosure.
Other features include local manual control, indication feedback via
dry contacts and 4-20 mA signal; or optional digital control via Modbus,
Foundation Fieldbus, Profibus, DeviceNet or Rotork Pakscan communication

systems.TheEHRangecanbesuppliedforoperationwithvirtuallyany
singlephase,threephase,or24VDCpowersupply.

Visit our web site at www.rotork.comformoreinformationontheEH,
Insight II and other Rotork actuator ranges.

4III

Identifying Actuator Parts

IV

5

Filler/Breather

Manual
Override
Pump

Hydraulic
Reservoir

Oil Drain
Plug

Pump

Motor

Manual Override Lever

SpeedControl
Valves

1/2" NPT

CableEntries

1/2" NPT

CableEntries

Manifold

Actuator

CenterBody

HydraulicCylinder

Accumulator

(Ifapplicable)

TerminalCompartment

Local/Remote
Switch

Open/Close
Switch

Display Window

SpringCanister
(Ifapplicable)

Local/Remote Switch

Open/Close
Switch

Control
Module

CONTENTS

Section Page

1 Health and Safety 1
2 Storage 3
3 Operating your EH Pro Actuator 4

3.1 ElectricalOperation 4

3.2 Display – Local Indication 4

3.3 Display Status Indication – Travel 5
 3.4 DisplayStatusIndication –Control 5

3.5 Display Alarm Indication 6

 3.6 ESDSignal 7
 3.7 PartialStroke 7
 3.8 LimitSwitches 7
 3.9 SpeedControl 7

4 Optional Manual Operation 8
5 Mounting the Actuator 9

5.1 Lifting 9

5.2 Mounting Orientation 9

5.3 Fitting to Valve 9

 5.4 MechanicalTravelAdjustment  9
 5.5 HydraulicFluid 9

5.6 Power Accumulators 9

6 Cable Connections 10

6.1 Earth/GroundConnections 10

 6.2 RemovingTerminalCover  10
 6.3 CableEntry 10
 6.4 ConnectingtoTerminals  11

Section Page

 6.5 ReplacingTerminalCover  11

7Commissioning 12

7.1 SettingProcedure 12
 7.2 RotorkSettingTool (oldversion) 13
 7.3 RotorkSettingTool Pro 14
 7.4 RotorkBluetooth
 7.5
 7.6 SettingMode– Password 17
 7.7 NewPassword[PC] 17
 7.8 CheckingMode 17
 7.9 BluetoothDiagnostics& Configuration 18
 7.10 PartialStrokeTest 18
 7.11 FullStrokeTest 19
 7.12 Crossroad[Cr] 19
 7.13
 7.14 ReturningtoValvePositionDisplay 20

EnteringtheActuatorSettingProcedure

ActuatorDisplay–Setting/CheckingMode

8 Commissioning – Basic Functions 21

Viewing the Basic Settings 21

8.1 Menu Structure 28

9 Configuration Settings 29

ConfigurationSettingsContents 29

 9.1 AccessingConfigurationSettings 29
 9.2 IndicationContactsr1 30
 9.3 GeneralSettings 31
 9.4 DigitalControl 33
 9.5 ESD/Partial StrokeSettings 35

®

Setting Tool Pro 15

17

19

Section Page

 9.6 AnalogueControl1 39
 9.7 AnalogueControl2 41

9.8 Interrupter Timer 43

9.9 Service 46

9.10 Bus System Option – Pakscan 48

 9.11 BusSystemOption–Modbus[OP] 51
 9.12 BusSystemOption–ProfibusDP[OP] 54
 9.13 BusSystemOption–DeviceNet 57

9.14

10 Maintenance, Monitoring
and Troubleshooting

10.1 Maintenance, Monitoring 64
and Troubleshooting

 10.2 Environmental 65

11 Help Screens 66
12 Weights and Measures 71

 12.1 Binary,Hexadecimaland 71
  DecimalConversionTable

13 Actuator Nameplate 72
14 Hazardous Area Approvals 73

 14.1 ApprovedFuses 73

15 Special Conditions of Safe Use 74
Appendix A

Accumulator Precharge and Removal

BusSystemPositioningControlSettings

64

60

V

1

Health and Safety

1

This manual is produced to enable a
competent user to install, operate,
adjust and inspect Rotork EH range of
actuators. Rotork EH range of actuators
may have features not covered in
this manual; always refer to order
specific operating documentation. Only
persons competent by virtue of their
training or experience should install,
maintain and repair Rotork actuators.
Work undertaken must be carried out
in accordance with the instructions
in this and other relevant manuals.
The user and those persons working
on this equipment should be familiar
with their responsibilities under any
statutory provisions relating to the
Health and Safety of their workplace.
Due consideration of additional
hazards should be taken when using
the EH range of actuators with other
equipment. Should further information
and guidance relating to the safe use
of the Rotork EH range of actuators be
required, it will be provided on request.

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 his duties under the Health
and Safety Act 1974.

For the USA: NFPA70, National

Electrical Code ® is applicable.
The mechanical installation should be

carried out as outlined in the manual
and also in accordance with relevant
standards. Since Rotork EH range
actuators may include features not
covered in this manual, always refer
to order specific documentation,
including operating instruction,
hydraulic schematic (HS) and wiring
diagram (WD). If the actuator has
nameplates indicating that it is suitable
for installation in hazardous areas then
the actuator may be installed in Zone
1 and Zone 2 classified hazardous area
locations only. It should not be installed
in hazardous area locations with an
ignition temperature less than 135 °C
unless suitability for lower ignition
temperatures has been indicated on the
actuator nameplate.

,

It should only be installed in hazardous
area locations compatible with the gas
groups stated on the nameplate.

The electrical installation, maintenance
and the use of the actuator should be
carried out in accordance with the code
of practice relevant for that particular
hazardous area certification.

No inspection or repair should be
undertaken unless it conforms to the
specific hazardous area certification
requirements. Under no circumstances
should any modification or alteration be
carried out on the actuator as this could
invalidate the actuators hazardous area
approval certification.

Access to live electrical conductors is
forbidden in the hazardous area unless
this 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.

Trained service technicians are
available to assist with or perform
commissioning and maintenance. If
you have any questions or concerns
regarding installation, commissioning,
maintenance, or operation, contact your
local Rotork office for assistance.

EH actuators utilise hydraulic fluid.
Refer to applicable specification for type
required.

Always wear safety glasses and
appropriate protective clothing
including gloves when working with
hydraulic fluid. Also remove any jewelry
or other objects that might conduct
electricity.

Prior to performing any maintenance,
make sure that electric power to the
actuator is removed and that hydraulic
system pressure is released.

Hydraulic fluid is a hazardous material.
Consult the material safety data sheet
(MSDS) for detailed health and safety
information. Fluids should be contained
and disposed of properly in accordance
with applicable regulations.

2

NING: Compressed Springs

WAR

All springs within the EH range of
actuators are pre-compressed. Springs
must not be removed from the actuator.

WARNING: Hydraulic Fluid

EH actuators are filled with hydraulic
fluid. See actuator data label for type of
oil supplied.

Should there be a requirement to
change the fluid, then the appropriate
protective clothing including gloves
and safety glasses must be worn. Used
hydraulic fluid must be disposed of
safely (see environmental section).

Note: the PRODUCT SAFETY DATA
SHEETS covering the type of
hydraulic oil supplied by Rotork
Fluid Systems for use within the
supplied power units are available
on request.

WARNING: Operating by Hand

With respect to optional manual
operation of Rotork Fluid Systems
actuators, see warnings in Section 4.

WARNING:

and operate when remote is selected.
This will be dependent on remote
control signal status and actuator
configuration.

WARNING:

only be located in areas where the risk
of impact to the viewing window is low.

Actuator may start

This actuator must

2

3

Storage

Actuator Materials
EH

EH enclosure: Aluminium,
Carbon steel
fasteners,
Stainless steel

Actuator body: Carbon steel

Power unit: Aluminium, Steel

Motor: Steel
Copper winding

Piston rod: Plated steel

Switchbox: Aluminium

Piping: Stainless steel
(hard piped)

External fasteners: Stainless steel

Paint finish: Standard 2-pack
epoxy brown red
(158 microns thick)

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.

Products manufactured by Rotork
Fluid Systems do not present a hazard
to health under normal conditions of
storage, distribution and use, provided
that good industrial and hygiene
procedures are followed.

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

If the actuator is to be installed, but not
immediately cabled, it is recommended
that any plastic cable entry transit plugs
be replaced with a suitable metal plug.

The double-sealed construction of the
terminal compartment will preserve
internal electrical components perfectly
if left undisturbed.

It is not necessary to remove the
electrical compartment covers in order
to commission the EH actuator.

Plug any open hydraulic ports or
electrical entries.

Fill the reservoir with the proper
hydraulic oil to protect the interior from
corrosion.

Visually inspect the equipment
periodically to identify any potential
corrosion. Repair as required.

Do not store in direct sunlight to avoid
premature weathering.

Rotork Fluid Systems will not accept
responsibility for deterioration caused
on site once the covers are removed.

Every Rotork Fluid Systems actuator
has been fully tested before leaving
the factory to give years of trouble
free operation, providing it is correctly
commissioned, installed and sealed.

Do not store in temperatures beyond
the normal operating range as stated
on data label.

3

Operating your EH Actuator

4

3.1 Electrical Operation

Check that the power supply voltage
agrees with that on the actuator
nameplate. Switch on power supply. It
is necessary to check phase rotation (on
3-phase units). Proper lead connections
can be verified by viewing the pump/
motor fan while in operation. It should
rotate clockwise. If rotation is anti­clockwise, reverse leads.

WARNING:

actuator electrically without first
checking, using the setting tool that
at least the Basic Settings have been
made.

Refer to Section 8.

Do not operate the

Selecting Local/Stop/Remote
Operation

The selector enables either Local or
Remote control, lockable in each position
using a padlock with a 6.5mm hasp.

When the selector is locked in the Local
or Remote positions the Stop facility is
still available. The selector can also be
locked in the Stop position to prevent
electrical operation by Local or Remote
control.

Local Control

With the selector positioned at Local
(clockwise) the lower black knob can
be turned to select Open or Close. For
Stop, turn upper knob anti-clockwise.
Fig. 3.1.

Local/Remote
Switch

Open/Close
Switch

Fig. 3.1.

Remote Control

Rotate the selector to the Remote
position (anti-clockwise), this allows
remote control signals to operate the
actuator. Local Stop can still be used by
turning the upper knob clockwise.

3.2 Display–Local Indication

Fig. 3.2 The Actuator Display

The display consists of:

1. Position Display – This is the main

7-segment position display with icons.

2. Text Display – This is a 2 line, 16
characters dot matrix display which
allows text to be used to compliment
the position display and icons.

3. Infrared LED's.

4. 2 x LED's for position indication.

Alarm Icon – This will be displayed

5.

for Valve, Control, and Actuator alarms.
Alarm indication is supported by fault

description text in the lower display.

6. IR Icon – This icon flashes during
infrared communication activity.

7. Percentage Open Icon – This icon will
be displayed when a percentage
Open value is in the upper display.

8. System Pressure – Hydraulic system
pressure is indicated by a gauge
on the manifold. The pump will
run automatically as required to
maintain adequate system pressure.
For actuators with accumulators, the
motor is controlled by an internal or
external pressure switch.

On power up the actuator’s liquid
crystal display screen is back-lit with an
amber light and one of the indicator
LED's will be on, dependent on
position. The display screen will show
percentage open or an end of travel
symbol. (See Figs 3.3, 3.4 and 3.5)

As standard, the red LED signifies valve
open, amber intermediate, and green
valve closed. Open and closed colour
functions can be reversed on request.

3

Operating your EH Actuator continued

5

Open

The Red LED will be lit, the open symbol
and "Open Limit" will be displayed.

Open Limit

Fig. 3.3

Mid Travel

The Amber LED will be lit, percentage
open value will be shown and "Stopped"
will be displayed when there is no
actuator movement.

Stopped

Fig. 3.4

Closed

The Green
and "Closed Limit" will be displayed.

LED will be lit

, closed symbol

Closed Limit

Fig. 3.5

LED Indicators

WARNING: Mid Travel LED
colour may be affected by viewing
angle and lighting level.

The Close LED colour can be changed
to red if required. Refer to section 9.3.

3.3 Display Status Indication
– Travel

The EH display provides real time
status indication. The top line of the
text display is reserved for travel status
indication. Fig 3.6 shows the travel
status example

Closed Limit

.

Closed Limit

Fig. 3.6

Available travel status conditions displayed:

•

Closed Limit

set closed limit position.

Open Limit

•

set open limit position.

Moving Open

•

the open direction.

Moving Closed

•

the closed direction.

Stopped

•

mid travel position, indicated in the
top display (%open).

Actuator has reached the

Actuator has reached the

Actuator is traveling in

Actuator is traveling in

Actuator has stopped in a

•

Timer Active

enabled only. Interrupter Timer has
stopped the actuator mid travel for a
period equal to the set Timer Off
time. Refer to section 9.8.

3.4 Display Status Indication
– Control

The bottom line of the text display is
reserved for control status indication
and is displayed for approximately 2
seconds after the control mode or
signal is applied. Fig 3.7 shows the
control status example

Interrupter Timer option

Remote Control

.

Closed Limit

Remote Control

Fig. 3.7

Available control status conditions displayed:

•

Local Control

Local Stop

•

Remote Control

•

selected.

Local control selected.

Local stop selected.

Remote control

3

Operating your EH Actuator continued

6

•

Local Close

Local close signal applied.

Local Open

•

•

or analogue) signal applied.

•

or analogue) signal applied.

•

emergency shut down signal applied.

•

signal applied.

•

signal applied.

•

emergency shut down signal applied.

•

via Bluetooth to either a setting tool
or PC.

* Bus Control option fitted may be Pakscan,

Local open signal applied.

Remote Close

Remote Open

Remote ESD

Remote Bus Open

Remote Bus Close

Remote Bus ESD

BT Connected

Profibus, Modbus, DeviceNet or Foundation
Fieldbus. Refer to actuator wiring diagram.

Remote close

Remote open

Remote hardwired

Remote Bus * open

Remote Bus* close

Remote Bus*

The actuator is connected

(hardwired

(hardwired

3.5 Display Alarm Indication

The EH display provides alarm indication
in the form of text and alarm icons.

General Alarm:

The general alarm icon will be
supported with text in the bottom line
indicating the particular alarm, or if
more than one is present, each alarm
will be displayed in sequence.

Fig 3.8 shows the status example

TRAVEL OP

(Mid Travel Over Pressure).

Stopped

MID TRAVEL OP

Fig. 3.8

Available alarm conditions displayed:

Valve Alarms

•OP IN MID POS - Tripped off on pressure

while moving in either direction between
electrical limits after a signal to move.

•OP AT LIMIT - Tripped off on pressure

while moving in either direction between
the electrical limit and the mechanical
end stop after a signal to move.

•STALL IN MID POS - No movement

detected between electrical limits after a
signal to move.

•STALL AT LIMIT - No movement detected

MID

between the electrical limit and the
mechanical end stop after a signal to
move.

Control Alarms

•DEMAND FAULT - This fault indicates
that the analogue demand signal has
dropped below half the minimum set
demand signal. In a 4-20 mA system the
demand signal has dropped below 2
mA, or it goes above 22mA.

•PS UNABLE TO RUN - The actuator may
not be at the correct limit to start the
test or a new command was issued
before the test was complete.

•MANUAL RESET ON - The actuator needs
to be manually reset after either a ESD
command or mains failure. Refer to 9.5

ESD Manual Reset.

•ESD ACTIVE - When present the ESD
signal overrides all local and remote
control signals. Once the ESD action is
carried out operation is inhibited while
the ESD signal is maintained. Refer to

9.5 ESD Action.

Actuator Alarms

• CONFIG ERROR - There may be an error
in the configuration (set up) of the
actuator. Check and reset basic setting
and check configuration settings.

•ELECTRONIC FAULT - A hardware fault is

caused by an internal fault on the Main
PCBA which prevents it from reading
its inputs. This is critical and inhibits
operation. This fault may be cleared by
removing the mains power from the
actuator and waiting for 20 seconds.

•LOCAL CONTROL FAIL - This indicates a
fault caused by a either a Main Board
failure, local control switch failure or
conflicting signals from the switches.
For example, both Local and Remote or
Open and Close selected simultaneously.

•SOL DRIVE FAULT - Contact Rotork.

• POS SENSOR FAULT - Detected failure in

the position sensing system – contact
Rotork.

•PRES SENSE FAULT - Detected failure in
the pressure sensing system – contact
Rotork.

•WRONG DIRECTION - This indicates
that the actuator has started to move
in the opposite direction to the given
command. When this occurs the
actuator is stopped.

• PS ERROR - This indicates that a fault
occurred while the actuator was
attempting a partial stroke.

•OPTION CH 1 FAULT - Contact Rotork.

•OPTION CH 2 FAULT - Contact Rotork.

•EEPROM MISSING - Contact Rotork.

3

Operating your EH Actuator continued

7

3.6 ESD Signal

A dedicated ESD digital input is
provided with all standard actuators.
The actuator may be configured to Fail­in- Position, Fail Close or Fail Open. The
ESD signal can also be configured to
override the Local Stop command.

Double -acting units without an
optional accumulator require power
to the motor in order to stroke the
actuator to the ESD position.

Refer to the wiring diagram for input
terminals. Refer to Section 9.5 for
settings.

3.7 Partial Stroke

A dedicated Partial Stroke input is
provided as a standard feature for
Open/Close applications. Its purpose is
to verify valve and actuator operation
without significant effect on valve flow.

Refer to the wiring diagram for input
terminals. Refer to Section 9.5 for
settings.

3.8 Limit Switches

When fitted, open and close limit
switches are pre-set at the factory to
correspond to the actuator mechanical
travel stops. Pre-set positions should
be checked to ensure full opening and
closing of the valve.

Should adjustment be required, they
must be manually set and are accessed
by removal of the control module cover.
The upper-most switch is the open
switch; the lower is the close switch.

Switch cam adjustment is by fingertip
rotation in either direction. Cams are
compression spring loaded and are held
in position by tapered centers.

Open and Close position limits must
also be set via controller configuration.
Refer to Section 8.

3.8.1 Open Switch Adjustment

Move the valve/actuator to the fully
open position. Locate the proper switch
cam. Push the cam down and rotate
anti-clockwise until the switch operates
and release the cam. The switch is now
set.

3.8. 2 Closed Swtch Ad justment

Move the valve/actuator to the fully
closed position. Locate the proper
switch cam. Lift and turn the cam
clockwise until the switch operates and
release the cam. The switch is now set.

3.8.3 Four SPDT Option

Refer to DOC 1613.

3.9 Speed Control

Speed control is a standard feature only
on the spring stroke of spring return
actuators. For the hydraulic stroke of
spring-return actuators and for double­acting actuators, it is an available option
requiring the addition of a hydraulic
power storage accumulator.

The speed of the hydraulic stroke is not
adjustable by the Extend speed control.
This is due to the nature of fixed
displacement pumps. The Extend speed
control should be fully anti-clockwise.

3.9.1 Sprin g-Return Adjustment

(No Accumulator)

Only the stroke time for the spring
stroke is adjustable. This is done with
the needle valve labeled Retract on the
hydraulic manifold. Loosen the jam nut
and turn the needle valve clockwise
to decrease the stroke time or anti­clockwise to increase stroke time.

The speed of the hydraulic stroke is not
adjustable by the Extend speed control.
This is due to the nature of fixed
displacement pumps. The Extend speed
control should be fully anti-clockwise.

3

Operating your EH Actuator continued

4

Optional Manual Operation

8

3.9.2 Spring-Return Adjustment
(Accumulator Fitted)

Speed Control of the spring stroke
is adjusted as outlined in Section

3.9.1.The hydraulic stroke is adjusted
by the Extend needle valve. Loosen the
jam nut and turn the valve clockwise to
decrease stroke time and anti-clockwise
to increase stroke time.

3.9.3 Spring-Return Units for
Positioning Applications

Positioning units will have an additional
speed control labeled Retract Slow.
This is used to slow the spring stroke
as the actuator approaches its demand
position. This will be factory set to
maximize positioning accuracy and
should not need adjusting.

3.9.4 Double-Acting Adjustment
(Accumulator Fitted)

Speed control of double-acting units
is not possible unless a hydraulic
accumulator is supplied.

The speed control labeled NV-EXT and
NV-RET are used to adjust the stroke
time. Loosen the jam nut and turn the
appropriate valve clockwise to decrease
and anti-clockwise to increase.

3.9.5 Double-Acting Adjustment
(No Accumulator)

Speed control is not available on
double-acting units without an
accumulator. This is due to the nature
of fixed displacement pumps.

Optional manual operation may have
been specified for your EH actuator.
For all EH actuators, optional manual
operation is provided with a hydraulic
hand pump. When supplied, a pump
with a removable handle is located on
or near the power unit.

WARNING:

Manual override operation should
only be carried out when there is no
power supplied to the actuator.

Hand pump Operation

In most cases, a two-position lever
on the side of the manifold selects
the direction of travel. Some special
actuators have a ball valve(s) to control
hand pump operation. Consult your
job specific hydraulic schematic for
operation details..

WARNING:

See specific manual override label
as supplied with actuator, for
manual override procedure.

For units fitted with an external
solenoid valve, an extra isolating
valve is fitted inline with the valve,
this must be set to ‘Manual’ to
operate the manual override.

An isolation valve is also fitted for
fail in position actuators, this must
be set to ‘Manual’ to operate the
manual override.

There is also a locking mechanism
fitted to each ball valve to allow it
to be locked in position by means of
a padlock. It is recommended that a
padlock is fitted for actuators being
used in an ESD application.

5

Mounting the Actuator

9

5.1 Lifting
WARNING:

Refer to weights and measures
from job specific EH information for
actuator weight.

Ensure the valve is secure before fitting
the actuator as the combination may be
top heavy and therefore unstable.

In no circumstances should hydraulic
piping or electrical cabling be used for
lifting purposes.

If it is necessary to lift the actuator
using mechanical lifting equipment,
certified slings should be attached.
At all times trained and experienced
personnel should ensure safe lifting,
particularly when mounting actuators.

WARNING: The actuator should

be fully supported until complete
valve shaft engagement is achieved
and the actuator is secured to the
valve mounting flange.

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.

5.2 Mounting Orientation

Refer to order specific installation
drawing for proper mounting
orientation.

5.3 Fitting to Valve

Refer to order specific installation
drawing for proper fitup and mounting
pattern to valve.

5.4 Mechanical Travel
Adjustment

When the actuator has been bolted
to the valve flange or adaptor and
keys inserted; the position of the stop
bolts should be checked to ensure full
opening and closing of the valve.

If the preset end positions are not
suitable, the stop bolts may be adjusted
by first loosening the jam nut and
screwing the bolts in or out until the
desired position is obtained. Stroke the
yoke away from the stop bolt when
adjusting then return to check position.
When the correct position is obtained,
re-tighten the jam nut.

Certain valves incorporate their own
stops. In these cases, it is recommended
that the actuator stop bolt positions
coincide with the valve stop positions.

5.5 Hydraulic Fluid

EH actuators are supplied without
hydraulic fluid and must be filled prior
to operation. See Section 10.1 for the
oil specification.

WARNING:
If the actuator is fitted with an
accumulator it must be drained to
the reservoir before adding oil.

With the spring, or for double-acting
actuators the piston, fully extended,
fill the reservoir to approximately 50
mm (2 inches) below the top. Stroke
the actuator two times and re-check
the reservoir level. Add additional oil as
required. Refer to Section 10.1 for the
oil specification.

5.6 Power Accumulators

Some EH Range actuator configurations
are equipped with hydraulic
accumulators to store energy for
stroking the actuator.

Accumulators must be pre-charged with
dry nitrogen prior to operation. See
Appendix A.

6

Cable Connections

10

WARNING:

Ensure all power supplies are
isolated before removing actuator
covers.

Check that the supply voltage is the
same as that stated on the actuator
nameplate.

A switch or circuit breaker must be
included in the wiring installation to
the actuator. The switch or circuit
breaker shall be mounted as close
to the actuator as possible and
shall be marked to indicate that it
is the disconnecting device for that
particular actuator. The actuator must
be protected with a suitably rated
overcurrent protection device as defined
on the applicable wiring diagram.

6.1 Earth/Ground Connections

An M8 X 1.0 earth stud is located
adjacent to the conduit entries for
attachment of an external protective
earthing strap. An internal earth terminal
is also provided on the terminal bung,
however it must not be used alone as
the protective Earth Connection.

6.2 Removing Terminal Cover

Using a 6mm hexagon key loosen the
four captive screws evenly. 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.

Fig. 6.1.

A plastic bag with the actuator contains
the following:

• Terminalscrewsandwashers.

• Sparecovero-ringseal.

• Wiringdiagram.

• Instructionbook.

Fig. 6.2.

6.3 Cable Entry

The four cable entries on the actuator
terminal housing are tapped ½” NPT.

Only appropriate certified Explosion­Proof entry reducers, glands or conduit
may be used in hazardous locations.

Remove any red plastic transit plugs.
Make cable entries appropriate to
the cable type and size. Ensure that
threaded adaptors, cable glands or
conduit are tight and fully waterproof.
Seal unused cable entries with a steel or
brass threaded plug. In hazardous areas
an appropriately certified threaded
blanking plug must be used.

6

Cable Connections continued

11

6.4 Connecting to Terminals

On EExde enclosure units
connections to the power and
control terminals must be made
using AMP type 160292 ring tabs for
power and earth terminals and AMP
type 34148 ring tabs for the control
terminals.

Refer to the wiring diagram inside the
terminal cover to identify functions of
terminals. Check that supply voltage
is the same as that marked on the
actuator nameplate.

Remove the red power terminal screen.

Begin by connecting these cables and
replace the red power terminal screen.

When all connections are made, ensure
wiring diagram is replaced in the
terminal compartment.

6.5 Replacing Terminal Cover

Ensure cover o-ring seal and spigot
joint are in good condition and lightly
greased before re-fitting cover.

WARNING:

plug is always tight before stroking
the actuator in either direction.

Ensure the oil fill

Heading

ATTENTION: RED PLASTIC PLUGS IN CONDUIT ENTRIES ARE FOR TRANSIT ONLY.

FOR LONG TERM PROTECTION FIT SUITABLE METAL PLUGS.

ATTENZIONE: I TAPPI IN PLASTICA ROSSA PER L'ENTRATA CAVI SONO SOLO
TEMPORANEI. PER UNA PROTEZIONE PERMANENTE PREGO SOSTITUIRLI CON

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

SON UNICAMENTE PARA TRANSPORTE. PARA PROTECCION PERMANENTE

ACHTUNG: DIE ROTEN PLASTIKSTOPFEN SIND NUR FÜR DEN TRANSPORT GEEIGNET.

FÜR DAVERHAFTEN SCHUTZ SIND DIESE GEGEN GEEIGNETE BLINDSTOPFEN

ATTENTION: LES BOUCHONS PLASTIQUES ASSURENT UNE PROTECTION

TEMPORAIRE. POUR UNE PROTECTION DEFINITIVE UTILISER DES BOUCHONS

APPOSITI TAPPI METALLICI.

COLOCAR TAPONES METALICOS APROPIADOS.

AUSZÜTAUSCHEN.

METALLIQUES.

7

Commissioning

12

7.1 The Setting Procedure

The Rotork Fluid Systems EH actuators
are designed so that commissioning
may be carried out without removing
any electrical covers.

Setting the internal hydraulic pressure,
limit and other functions is achieved
by using the Infrared Setting Tool. The
Setting Tool is certified Intrinsically Safe
to allow commissioning in hazardous
areas.

All the commissioning functions are
stored in non-volatile memory in the
actuator. The Setting Tool enables the
user to view all the functions in turn
via the actuator display window. As
each function is viewed its setting can
be checked and, if required, changed
within the bounds of that function.

The power supply must be connected
and energised for commissioning
purposes. The setting procedure is
divided into two stages:

1. Basic Settings

Setting end of travel limit actions,
pressure values and limit
positions.

2. Configuration Settings

Settings covering the control,
indication and optional
equipment functions.

All EH actuator functions are
configured before despatch
to Rotork Fluid Systems
standard default settings
unless alternatives have been
specified with the order. Should
difficulty be encountered during
commissioning the default
settings can be reinstated,
returning the actuator
configuration to its original
manufactured state. Site
commissioning can then begin
again.

The default function should be used
with caution as settings selected after
manufacture may be essential for
the safe operation of the valve and/
or plant.

Actuator Display

Position Display

or a percentage open value.

Pressure and Position

Password P?

Crossroad cr

Basic Settings Configuration Settings

Limit Actions Indication Contacts
Pressure Values Control Mode
Limit Positions Options
Help Screens
Defaults

Note: The Basic Settings must be commissioned first.

50

This may be an open or closed symbol

m

50

Refer to Section 10.

Torque

m

PC k Bt k Pt k FT

k

m

k

m

7

Commissioning continued

13

7.2 Rotork Setting Tool (old version)
Specification

Enclosure IP67

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)

Name Instruction

1. m Key* Display next function down

Key* Display next function across

2.

k

-

Key Decrease/change displayed function’s value or option setting

3.

+

Key Increase/change displayed function’s value or option setting

4.

Key Enter displayed value or option setting

5.

Infrared local operation (when enabled)

Key Non-functional on EH actuators

6.

Key Non-functional on EH actuators

7.

8. Infrared Transmitter Window

* Pressing the two arrow keys together returns the actuator display to the position
indication mode

8

1

3

5

7

Fig. 7.1 Rotork Setting Tool

2

4

6

7

Commissioning continued

14

7.3 Rotork Setting Tool Pro

Name Instruction

1. m Key* Display next function down.

i Key Display previous function up.

2.

Key* Display next function across right.

3.

k

o

Key Display previous function across left.

4.

-

Key Decrease/change displayed function’s value or option setting.

5.

+

Key Increase/change displayed function’s value or option setting.

6.

Key Non-functional on EH actuators.

7.

Key Enter displayed value or option setting.

8.

9. Infrared transmitter window.

Key Non-functional on EH actuators.

10.

Key Non-functional on EH actuators.

11.

* Pressing these two arrow keys together exits setting mode and returns the
actuator display to the pressure/position indication mode.

2

9

8

3

6

7

11

4

5

1

Fig. 7.3. Rotork Setting Tool Pro

Specification

Enclosure: IP54
Certification: ATEX CE 0518 Ex II 1G

FM, INT SAFE, Class I, Div 1, Groups A, B, C & D, T4.
CSA, Exia, Class I, Div 1, Groups A, B, C & D, T4.

Temperature: Tamb = -30 ºC to 50 ºC
Power supply: 2x 1.5V AA Batteries (supplied and fitted)
Operating range: 0.75m (from actuator display window)

10

7

Commissioning continued

15

7.4 Rotork Bluetooth® Setting Tool Pro

Name Instruction

1. m Key* Display next function down.

i Key Display previous function up.

2.

Key* Display next function across right.

3.

k

o

Key Display previous function across left.

4.

-

Key Decrease/change displayed function’s value or option setting.

5.

+

Key Increase/change displayed function’s value or option setting.

6.

Key Initiate download/upload via Bluetooth.

7.

Key Enter displayed value or option setting.

8.

9. Infrared transmitter window.

Key Non-functional on EH actuators.

10.

Key Non-functional on EH actuators.

11.

* Pressing these two arrow keys together exits setting mode and returns the
actuator display to the pressure/position indication mode.

2

9

8

4

5

3

6

7

11

1

10

®

Fig. 7.4. Rotork Bluetooth

Specification

Enclosure: IP54
Certification: ATEX CE 0518 Ex II 1G

FM, INT SAFE, Class I, Div 1, Groups A, B, C & D, T4.
CSA, Exia, Class I, Div 1, Groups A, B, C & D, T4.

Temperature: Tamb = -30 ºC to 50 ºC
Power supply: 4 x 1.5V AAA Batteries (supplied and fitted)
Operating range: Infrared: 0.75m (from actuator display window)

Bluetooth: 3m (from actuator display window)

Setting Tool Pro

7

Commissioning continued

16

Setting Tool Battery Replacement

Battery status can be checked by
looking at the Infrared transmitter
window while depressing any Setting
Tool button. A flashing red indicator
should be seen.

Battery replacement must be
carried out in a safe area. To replace
the battery remove the six caphead
screws in the back of the Setting
Tool. Remove the back cover to
expose the battery.

The Setting Tool (old version):

In order to maintain hazardous
area certification fit only Duracell
mN1604 or Rayovac Alkaline
maximum NoAL-9V battery types.

The Setting Tool Pro:

In order to maintain hazardous
area certification fit only with
the following AA size, Alkaline­Manganese, approved battery types:

Duracell, Coppertop, type MN1500
Duracell, Procell, type MN1500
GP, Super Alkaline, type GP15A

Other types of AA size batteries,
including Duracell, Ultra, type
MN1500, must not be fitted.

The Rotork Bluetooth® Setting
Tool Pro:

In order to maintain hazardous
area certification fit only with
the following AAA size, Alkaline­Manganese or Zinc-Manganese
approved battery types:

Duracell, Procell, type MN2400
Energizer, type E92.

Refit cover ensuring red indicator
LED faces the transmitter window in
the back cover.

When a button is depressed the Setting
Tool transmits the relevant instruction
to the actuator by infrared pulses and
must therefore be directly in front of
the actuator indicator window and at a
distance no greater than 0.75m.

The enclosure of the Rotork Setting Tool

Pro, and Rotork Bluetooth
Pro, is manufactured from the following

materials:

Polycarbonate, ABS blend
Polycarbonate
Silicon Rubber

If the Rotork Setting Tool Pro and Rotork

Bluetooth® Setting Tool

to come into contact with aggressive
substances (e.g. solvents that may affect

®

Setting Tool

Pro

are likely

polymetric materials), then it is the
responsibility
precautions (e.g. regular checks as part
of the routine inspections or establishing
that the materials are resistant to the
specific chemical) that prevent it from
being adversely affected, thus ensuring
that the type of protection is not too
compromised.

No form of repair must be
attempted on any of the actuator
Setting Tools.

of the user to take suitable

Download / Upload Function

This new feature has been introduced
with the new Rotork Bluetooth® Setting
Tool Pro. It allows the user to download
datalogger files and download/upload
configuration files. The new tool is
weatherproof and intrinsically safe and
so it can be used safely in all environments.

Refer to Bluetooth® Setting Tool Pro
publication PUB095-001.

Display Set-Up Mode

The Setting Tool and Setting Tool arrow
keys are used to access and navigate
through the actuator set-up procedure
using the actuator display. Each actuator
function with it's current setting is
represented on screen by a combination

Function
Code

Close Action

Function

Function
Code

Stop on Pressure

Open Pressure

Function

of code and text.

The Setting Tool change keys (+ and
–) allow the user to view the available
setting options.

The examples of displayed functions

Close Action, [C2] and Open
Pressure

Note that a setting option or value is
highligh

This instruction manual uses both code
and text for description.

at Limit 90%

, [OP] are shown above.

ted.

Setting

Code

Setting

Option

Setting

Value

Setting

Value

7

Commissioning continued

17

7.5 Entering the Actuator
Setting Procedure

With the actuator securely mounted
on the valve, the mains supply on and
Local control or Stop selected.

PRESS THE m KEY.

The actuator upper display will remain
the same and the lower display will
change to Pressure value. This will be
represented by Pressure = XX%,XXBAR
or XXPSI and a bar graph.

PRESS THE m KEY.

The actuator display will change and
the password protection display will be
seen.

Enter Password

1D Hex

The Actuator Function Settings

can be protected by the Use

of a Password

7.6 Setting Mode – Password

To enable setting and adjustment of the
actuator functions the correct password
must be entered. The factory set (default)
password is [ld]. If the actuator has
previously been set with a site password
this must be entered.

+

-

or

Use the
available passwords 00–FF (hexadecimal).
With the correct password displayed press
the enter key.

keys to scroll through the

PRESS THE KEY.

Two “setting” bars will appear and will
remain visible on every function display
screen. In addition, "Password Correct"
will be displayed for 3 seconds.

Enter Password

Password Correct

Default Password,

Setting Mode Enabled

7.7 New Password [PC]

To configure a new password, the
actuator must be in setting mode with the
password display – setting mode enabled
– showing,

PRESS THE

The display will change to [PC].
Using the

available passwords until the desired
password is displayed.

KEY.

k

+

or - key scroll through the

PRESS THE KEY.

Change Password

1E Hex

Password Changed to [IE]

NOTE: The new password becomes

effective the next time setting mode is
entered.

7.8 Checking Mode

The actuator function settings can be
checked without entering the correct
password. The settings can only be
viewed and not altered. The setting bars
will not be seen.

Enter Password

1D Hex

Password Display, Checking Mode

Once the procedure has been completed
in the required mode

PRESS THE m KEY.

The procedure branch [Cr] (crossroad)
display can now be seen.

7

Commissioning continued

18

7.9 Bluetooth Diagnostic and
Configuration

EH Pro actuators include a Bluetooth
interface as standard, allowing non­intrusive diagnostics, analysis and
configuration.

Insight II software for PC has been
developed to enable the actuator
configuration and onboard Datalogger
to be reconfigured and analysed. A PC
running Insight II software can be used
to interrogate the actuator via non­intrusive Bluetooth communication. Visit
www.rotork.com for information.

Alternatively, the intrinsically safe Rotork

Bluetooth® Setting Tool

user to extract and store EH actuator
configuration and Datalogger files
within the tool. Stored files can then be
uploaded via Bluetooth to a PC running
Insight II where they can be viewed,
analysed and stored in a safe, clean
environment.

Using the Rotork
Tool

Pro

, actuator setup can be
configured on the PC, stored in the
tool, transported to the actuator
and uploaded. The tool can transfer
the same configuration to multiple
actuators where actuator setup is the
same.

Pro

allows the

Bluetooth® Setting

Refer to PUB095-001-00 for full
instructions on the use of the Rotork
Bluetooth® Setting Tool

To enable communication with Insight
II, the actuators Bluetooth interface
must be enabled.

The default setting for the Bluetooth
interface is [OF] disabling Bluetooth.

[OF] Off (Default): Bluetooth is disabled
[ON] On: Bluetooth is permanently

enabled.
[LS] Local Stop Only: Bluetooth is only

enabled when the actuator is in Local
Stop.

To change this setting press the +
or – key until the required setting is
displayed.

Bluetooth Comms

Pro

.

Off

PRESS THE KEY.

The displayed option will flash (stored)
indicating that it has been set.

7.10 Partial Stroke Test

This function performs a partial stroke
test based on the parameters set in
[PP] and a setup test being completed
in [SP]. Insight II can then be used to
compare subsequent partial stroke
tests against the original test when the
actuator was first commissioned.

The actuator must be in Local to
perform a test.

The actuator needs to be moved to the
correct limit prior to initiating the test

[Pt] Perform the partial stroke test.

P-Stroke Te st

Confirm?

PRESS THE KEY.

P-Stroke Te st

- No +

This brings up an option to either
cancel or confirm that the partial stroke
test should be completed.

To cancel the test: Ensure that [No] is
displayed on the screen.

PRESS THE KEY.

To confirm that the test should be
completed: Press the + key until the
display changes to [Ys]

P-Stroke Te st

- Yes +

PRESS THE KEY.

7

Commissioning continued

19

7.11 Full Stroke Test

This function performs a full stroke test
based on a setup test being completed
in [SF]. Insight II can then be used to
compare subsequent full stroke tests
against the original test when the
actuator was first commissioned.

The actuator must be in Local to
perform a test.

The actuator needs to be moved to
either the closed or open limit prior to
initiating the test.

[Ft] Perform the partial stroke test.

Full Stroke Test

Confirm?

PRESS THE KEY.

Full Stroke Test

- No +

This brings up an option to either
cancel or confirm that the full stroke
test should be completed.

To cancel the test: Ensure that [No] is
displayed on the screen.

PRESS THE KEY.

To confirm that the test should be
completed: Press the + key until the
display changes to [yS]

Full Stroke Test

- Yes +

PRESS THE KEY.

7.12 Crossroad [Cr]

Basic Setup

Config Setup

To access the Basic Settings press the
arrowm key. Refer to 8.

To access the Configuration Settings
press the arrow

Section 9.

key. Refer to

k

7.13 The Actuator Display –
Setting/Checking Mode

Actuator functions as laid out in the
Basic and Configuration commissioning
stages, can be individually displayed by
using the Setting Tool arrow keys.

m

arrow key will always display the

The
FIRST function on the next level DOWN
within the procedure.

arrow key will always display

The

k

the NEXT function on the SAME level
and will wrap around the functions on
the same level.

Actuator functions are displayed in code
form in the top left portion of the liquid
crystal display screen.

The setting for the displayed function is
shown in the top right hand portion of
the screen. Depending on the actuator
function displayed, its setting may be
an option or a value.

Text relating to the function and setting
values will be displayed in the lower
display.

7

Commissioning continued

20

key.

Stored

+

"

In setting mode the Setting Tool

-

or

keys will cause the setting to be
changed. In checking mode the settings
cannot be altered.

In setting mode, once displayed, a new
setting can be entered into the actuator
memory by pressing the
The setting will flash off and back on,
confirming its selection, and "
will be displayed for 2 seconds in the
text display.

TOP LEFT
PORTION

Function e.g.

Open Pressure

at Limit 90%

OP = Open Pressure

TOP RIGHT
PORTION

Function Setting
e.g. Value = 90%

LOWER DISPLAY

Function: Open Pressure
Setting Value: 90%

7.14 Returning to Valve
Position Display

There are five ways of returning to valve
position display:

1. Approximately 5 minutes after the
last Setting Tool operation the
display will automatically return to
position display.

2. Press the
together.

3. Press the
display returns to position.

4. Press the
to position display.

5. Select Remote control using the
Local/Stop/Remote selector.

m

m

iarrow key to return

and

arrow keys

k

arrow key until the