rotork IQ3 Instructions For Safe Use, Installation, Basic Setup And Maintenance
IQ Range
Instructions for Safe Use, Installation,
Basic Setup and Maintenance
This manual contains important safety
information. Please ensure it is thoroughly
read and understood before installing,
operating or maintaining the equipment.
PUB002-039-00
Date of issue 03/18
Table of Contents
1. Introduction _____________________________3
1.1 Identif ying Actuator Parts ..................3
1.2 Rotork Set ting Tool .......................4
1.3 Introduction to this manual .................5
2. Health and Safety _______________________5
2.1 ATEX/IEC E X Certified Actuators .............7
3. Storage _________________________________7
4. Operating your IQ Actuator ______________8
4.1 Operating by Hand ........................8
4.2 Operating Electrically ......................8
4.3 Display - Local Indication ...................9
4.4 Display – Home screen selection ............10
4.5 Display Status Indication – Travel ............11
4.6 Display Status Indication – Control ...........11
4.7 Display Alarm Indication ...................11
4.8 Batter y Alarm ...........................11
5. Preparing the Drive Bush _______________ 12
5.1 IQ base all sizes types A and Z3 .............12
5.2 Non-Thrust Base Type B ...................13
2
6. Mounting the Actuator ________________ 14
6.1 Rising Stem Valves Top Mounted ............15
6.2 Valve with Gearbox – Side Mounting .........15
6.3 Non-Rising Stem Valves – Top Mounting ......15
6.4 Handwheel Sealing .......................16
6.5 IQM Modulating Ac tuators ................16
6.6 IQL & IQML Linear Drive Unit ...............16
6.7 IQL & IQML Adjusting Linear Stroke ..........17
7. Cable Connections _____________________ 17
7.1 Terminal Block Layout ....................17
7.2 Earth/Ground Connections. . . . . . . . . . . . . . . . .18
7.3 Removing Terminal Cover ..................18
7.4 Cable Entry .............................20
7.5 Connecting to Terminals ..................20
7.6 Replacing Terminal Cover ..................21
8. Commissioning - Basic Settings _________ 21
8.1 Connecting to the Actuator ................22
8.2 Securit y - Password ......................23
8.3 Basic Settings Menu ......................24
8.4 Basic Set tings – Limits ....................25
8.5 Close Settings ...........................26
8.6 Open Set tings. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8.7 Torque Switch Bypass .....................27
9. Maintenance, Monitoring and
Troubleshooting _______________________ 28
10. Environmental _________________________ 30
11. Weights and Measures _________________ 31
12. IQ Approvals __________________________ 32
13. Approved Fuses _______________________ 34
14. Vibration, Shock and Noise _____________ 34
15. Conditions of Safe Use _________________ 34
15.1 Thread details for ATEX and IECEx
Approved actuators ......................34
15.2 Maximum constructional flamepath gaps
for ATEX and IECEx Approved actuators. ......35
1. Introduction
1.1 Identifying Actuator Parts
Hand wheel
Oil plug
Control Cover
Name plate
Battery sealing plug
Metal (8 mm Allen key required)
Plastic (10 mm Allen key required)
as appropriate.
Hand / Auto lever
Display window
Oil plug
Side hand wheel
Motor
Base
Terminal Cover
Conduit entries
Local / Remote / Stop
selector
Open / Close selector
Oil plug
IQ3 manual – Se ction: Intr oductio n 3
1.2 Rotork Setting Tool
The Rotork Bluetooth® Setting Tool Pro
(BTST) combines the legacy IR and IrDA
communication protocols with the latest
Bluetooth
IrDA suppor t for older Rotork products is
retained (for use as an IR communication
tool, please refer to publications
PUB002-003 and PUB002-004).
The new BTST is able to connect to Rotork
Bluetooth
related software to setup and complete
missions. Missions are configurable
programs of instructions that are to be
performed by the BTST on an actuator and
include (but are not limited to) downloading
configuration and datalogger files as well
as uploading specific configurations to
the actuator. Different missions can be
programmed into the BTST via Insight2.
®
wireless technology. IR /
®
wireless enabled actuators and
Rotork Bluetooth® Setting Tool Pro
Specification
Enclosure:
Constructed in accordance with IEC 60529
to IP54.
The BTST has been built in accordance with
the following standards:
ATEX II 1 G, Ex ia IIC T4 Ga
IECEx – Ex ia I IC T4 Ga
USA – FM Int Safe Class I, Div 1, Groups A,
B, C & D, T4
Canada – CSA Exia Int Safe, Class I, Div 1,
Groups A, B, C & D, T4
Ambient Temperature Range:
Tamb = -30 °C to +50 °C
Operating Range:
Infra Red 0.75m
Bluetooth
Enclosure Materials:
Polycarbonate ABS blend, Polycarbonate
and Silicon Rubber
®
10m
Instructions for Safe Selection,
Installation, Use, Maintenance
& Repair
1. The BTST must only be used in hazardous
areas (potentially explosive atmosphere)
permitted by the equipment classification,
temperature class and ambient temperature
range stated above (this is also stated on
the back of the BTST).
2. The following checks must be conducted
on the BTST prior to taking it into a
hazardous area:
a. The BTST function must be checked by
ensuring that the red or green LED, either in
the clear window or under the ‘Enter’ key
of the BTST, illuminates when any button
is pressed. If an LED does not illuminate,
there is a potential functional problem with
the BTST and the inspection or battery
replacement stated below in paragraph 6
must be per formed.
b. If the BTST is likely to come in contact
with aggressive substances (e.g. solvents
that may affect polymeric materials), then
it is the responsibility of the user to take
suitable precautions (e.g. regular check s
as part of the routine inspections or
establishing that the enclosure materials
are resistant to the specific chemicals) that
prevent the BTST being adversely affected,
thus ensuring that the type of protection is
not compromised.
3. It is essential that the actuator settings
are checked for compatibilit y with the valve,
process and control system requirements
before the ac tuator is put into service.
4.
No user adjustment of the BTST is required.
5. The BTST must be inspected every three
months, in a safe (non-hazardous), dry area
by suitably trained personnel, to ensure it
has been maintained in accordance with the
applicable code of practice.
6. In accordance with the BTST
hazardous area approvals and with the
recommendations from the approved
battery suppliers, the following are
mandatory requirements for safe use:
a. The inspections or replacement of the
batteries must be conducted in a safe (nonhazardous), dry area.
b. The batteries must be removed from the
BTST when it is not expected to be used for
3 months or longer.
c. Discharged batteries must be removed
from the BTST to prevent possible damage.
d. The battery compartment of the BTST
must be inspected every 3 months for any
battery leakage. If any batter y leakage has
occurred then the BTST must not be used.
4 IQ3 manual – Se ction: Intr oductio n
e. Only the following approved AlkalineManganese or Zinc-Manganese type ‘AAA’
size batteries must be fitted to the BTST:
- Duracell: Procell MN2400
- Energizer: E92
f. Always replace all four batteries
at the same time. Always use four
unused batteries of the same approved
manufacturer, type and expiry date code.
g. Ensure the batteries are fitted with the
correct polarity. The batter y polarity (+)
is indicated on the inside of the batter y
compartment of the BTST.
7. The BTST contains no other user
replaceable parts and it cannot be repaired
by the user. If the BTST is faulty or needs
repairing, it must not be used.
1.3 Introduction to this manual
This manual provides instruction on:
• Manual and electrical (local and
remote) operation.
• Preparation and installation of the
actuator onto the valve.
• Basic commissioning.
• Maintenance.
Refer to Publication PUB002- 047
for repair, overhaul and spare part
instructions.
Refer to Publication PUB002- 040
for secondary function
configuration instructions.
Using the supplied Rotork Bluetooth®
Setting Tool Pro to access the actuator
set up procedures, non-intrusive
setting of torque levels, position limits
and all other control and indication
functions can be made safely, quickly
and conveniently, even in hazardous
locations. The IQ allows commissioning
and adjustment to be carried out with
the main power supply to the actuator
switched on or off.
The setting tool is packed in the
shipping box identified with a
yellow label.
Visit our web site at www.rotork.com
for more information on the IQ, Insight2
and other Rotork actuator ranges.
2. Health and Safety
This manual is produced to enable a
competent user to install, operate,
adjust and inspect Rotork IQ range valve
actuators. Only persons competent by
virtue of their training or experience
should install, maintain and repair
Rotork actuators.
Under no circumstances should
replacement parts be used in Rotork
actuators, other than those supplied or
specified by Rotork.
Work undertaken must be carried out in
accordance with the instructions in this
and any other relevant manuals.
If the actuator is used in a manner not
specified in this manual and any other
Rotork manual, the protection provided
by the actuator may be impaired.
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 IQ range of actuators with other
equipment. Should further information
and guidance relating to the safe use
of the Rotork IQ 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 this manual
and also in accordance with relevant
standards such as British Standard
Codes of Practice. If the actuator has
nameplates indicating that it is suitable
for installation in hazardous areas then
the actuator may be installed in Zone
1, Zone 21, Zone 2 and Zone 22 (or Div
1 or Div 2, class I or Class II) 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 and dust groups stated on the
nameplate.
IQ3 manual – Se ction: He alth and Safet y 5
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 cer tification. 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.
WARNING: Service Altitude
The actuator installation altitude must
be restricted to less than 2000 m
as defined by IEC61010-1 (Safety
requirements for electrical equipment
for measurement, control and
laboratory use).
WARNING: Motor Temperature
Under normal operation the
temperature of actuator’s motor cover
surfaces can exceed 60 °C above
ambient.
WARNING: Surface Temperature
The installer/user must ensure that the
actuator surface temperature rating
is not influenced by external heating/
cooling effect (e.g. valve/pipeline
process temperatures).
WARNING: Thermostat Bypass
If the actuator is configured to
bypass the motor thermostat then
the hazardous area certification will
be invalidated. Additional electrical
hazards may occur when using this
configuration. The user should ensure
that any necessary additional safety
measures are considered.
WARNING: Enclosure Materials
IQ Range of actuators are
manufactured from aluminium alloy
with stainless steel fasteners and the
thrust bases are manufactured in cast
iron.
The cover window is toughened glass
which is retained with a 2-part silicone
cement and the battery plug will be
either stainless steel or PPS (PolyPhenolyne Sulfide).
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
With respect to handwheel operation
of Rotork electric actuators, refer to
sec ti o n 4.1.
WARNING: Actuator may start
and operate when remote is
selected. This will be dependent on
remote control signal status and
actuator configuration.
6 IQ3 manual – Se ction: He alth and Safet y
2.1 ATEX/IEC EX Certified Actuators
Special Conditions
This actuator must only be located in
areas where the risk of impact to the
viewing window is low.
This equipment includes some
exterior non-metallic parts including
the protective coating. To avoid the
possibility of static build up, cleaning
must only be carried out with a damp
cloth.
WARNING:
External Enclosure
Fasteners
Enclosure fasteners are stainless steel
grade A4 80 except for the following
sizes and when marked on the
nameplate as shown. In these cases
the terminal cover fasteners are carbon
steel grade 12.9. If in doubt check the
grade marked on the relevant fastener
or contact Rotork.
Actuator Size: IQ/IQM/IQS 20 & 35
or IQ/IQM 25
Ex d IIB T4 Gb (-30°C to +70°C)
Ex d IIB T4 Gb (-40°C to +70°C)
Ex d IIB T4 Gb (-50°C to +40°C)
Certificate No: SIRA 12ATEX1123X or
IECEx SIR 12.0047X
Actuator Size: IQ/IQM 20 & 25 or
IQS20
Model: IQ3FM - Explosionproof, Class I,
Div 1, Groups B, C, D
FM Approved
3. 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 the plastic transit cable entry plugs
are replaced with metal plugs which
are sealed with PTFE tape.
The Rotork double-sealed construction
will preser ve internal electrical
components perfectly if left
undisturbed.
It is not necessary to remove any
electrical compartment covers in order
to commission the IQ 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.
IQ3 manual – Se ction: Stora ge 7
4. Operating your IQ Actuator
4.1 Operating by Hand
WARNING
With respect to handwheel
operation of Rotork electric
actuators, under no circumstances
should any additional lever device
such as a wheel-key or wrench
be applied to the handwheel in
order to develop more force when
closing or opening the valve as
this may cause damage to the
valve and/or actuator or may cause
the valve to become stuck in the
seated/ backseated position.
Keep clear of the handwheel
when engaging hand operation.
Actuators driving valves via
extension shafts may be subject
to retained shaft torsion which
can cause the handwheel to rotate
when hand operation is engaged.
To engage handwheel drive depress
the Hand/Auto lever into “Hand”
position and turn the handwheel to
engage the clutch. The lever can now
be released where it will return to its
original position. The handwheel will
remain engaged until the actuator
is operated electrically when it will
automatically disengage and return to
motor drive.
If required for local lockout purposes
the Hand/Auto lever can be locked in
either position using a padlock with a
6.5 mm hasp.
Locking the lever in the "hand"
position prevents electrical operation of
the actuator moving the valve.
4.2 Operating Electrically
Check that power supply voltage
agrees with that on the actuator
nameplate. Switch on power supply.
It is not necessary to check phase
rotation.
Do not operate the actuator
electrically without first checking,
using the infra-red Setting Tool,
that at least the Basic Settings have
been made (refer to Section 8).
Selecting Local/Stop/Remote
Operation
The red selector enables either Local
or Remote control, lockable in each
position using a padlock with a 6.5
mm 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.
Fig. 4.2.1 IQ3 Local Controls
Local Control
With the red selector positioned at
Local (anti- clockwise) the adjacent
black knob can be turned to select
Open or Close. For Stop, turn red knob
clockwise.
Remote Control
Rotate the red selector to the Remote
position (clockwise), this allows remote
control signals to operate the actuator.
Local Stop can still be used by turning
the red knob anti-clockwise.
8 IQ3 manual – Se ction: Op erating your I Q Actuato r
4.3 Display - Local Indication
2
8
9
5
Fig. 4.3.1 Segment Display
1. Position display
This is the main segment display for
position and torque; position indication
to 1 decimal place.
10
6
7
1
2. Analogue Scale
Scale 0% to 100% is used when
Analogue torque (% of rated) or
Positioning (% position / demand)
homescreens are selected. Refer to
section 4.4.
3. Infra-red LEDs
Used for older models of setting tool
and to initiate a data connection using
Bluetooth wireless technology.
4. Dual position LEDs
Consisting of 2 x Yellow for mid
position and 2 x bi-colour (Red / Green)
for end of travel indication.
5. Bluetooth indication LED
A dual intensity LED for indicating an
44
active connection using Bluetooth
wireless technology.
6. Alarm Icon
This will be displayed for valve, control
3
and actuator alarms. Alarm indication
is supported by fault description in the
text in the line above the main display.
7. Battery Alarm Icon
This icon will be displayed when
a battery is detected as low or
discharged. "Battery low" or
"Discharged" will also be displayed in
the text display above.
8. Infra-Red Icon
This icon flashes during setting tool
communication activity. LEDs will also
flash when keys are pressed.
9. Percentage Open Icon
This icon will be displayed when an
integer open value is displayed e.g.
57. 3 .
10. Dot Matrix Display
A high resolution 168x132 pixel
display for displaying setup menus and
datalogger graphs.
When a positional display is active,
the status and active alarms will be
displayed.
The LCD screen is made up of two
layers; the main segment display and
the dot matrix display. The displays
are dual stacked so that either display
can be enabled to show different
information. This also allows a
combination of both displays for added
flexibility.
On power the LCD is backlit with a
white light to enable the best viewing
contrast in all lighting conditions. For
additional positional indication, the
LEDs at either side of the LCD are used
for Closed (green), mid-travel (yellow)
and Open (red) as standard. These LEDs
are fully configurable in the settings
menu or on request at time of order.
IQ3 manual – Se ction: Op erating your I Q Actuato r 9
4.4 Display – Home screen selection
YY
1
2
3
44
5
6
7
8
9
10
1
2
3
44
5
6
7
8
9
10
The actuator display can be set to show
any one of the following home screens:
• Position indication
• Position & Digital Torque indication
•
Position & Analogue Torque indication
•
Position & Control Demand indication
The default home screen is Position.
Permanent Home Screen display.
Using the setting tool (refer to 8.1)
connect to the actuator.
From the Settings menu, select
Indication, Local Display. From
the available settings, select Home
Screen. Enter the password if
requested (refer to section 8.2), select
Home screen and from the dropdown
list, select the required Home screen
for permanent display:
Home screens indicate the live
conditions measured by the actuator
when mains power is applied. When
mains power is switched off the
actuator battery powers the display
and it will show the position indication
display only.
The required home screens can be
set by the user either as a permanent
display or as a temporary display for
valve or actuator operational analysis.
Temporary Home Screen display.
Using the setting tool (refer to 8.1)
or
the available home screens until
the required one is displayed. The
selected screen will remain displayed
for approximately 5 minutes after the
last setting tool command or until the
actuator power is cycled.
arrow keys, scroll through
Fig. 4.4.1 Home Screen Selection
Position
- Default valve position display
Torque (A) + Pos - Position with
analogue torque indication
Torque (D) + Pos - Position with
digital torque indication
Positioner - Position with digital and
analogue position demand indication
Once selected, the set display will be
the active, permanent home screen.
Refer to Figs 4.4.2 to 4.4.5.
Fig. 4.4.2 Position
Fig. 4.4.3 Torque (D) + Position
Fig. 4.4.4 Torque (A) + Position
Fig. 4.4.5 Positioner
10 IQ3 manual – S ection: O perating yo ur IQ Actuat or
4.5 Display Status Indication – Travel
The IQ display provides real-time status
indication. The top line of the text area
is reserved for travel status indication.
Fig 4.5.1 shows the travel status
example of CLOSED LIMIT
4.6 Display Status Indication – Control
The bottom line of the text area is
reserved for control status indication
and is displayed for approximately 2
seconds after the control mode or
signal is applied.
Fig 4.6.1 shows the control status
example Remote Control.
4.7 Display Alarm Indication
The IQ display provides alarm indication
in the form of text and alarm icons.
There are 2 alarm icons:
General Alarm:
Battery Alarm:
4.8 Battery Alarm
Fig. 4.5.1
Fig. 4.6.1
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 4.7.1 shows the status example:
TORQUE TRIP CLOSED
Fig. 4.7.1
Fig. 4.8.1
The actuator checks the battery level
at approximately 1 hour intervals. The
battery alarm icon is displayed when
the actuator detects its battery as
being low and the display will indicate
BAT TERY LOW. If the battery is flat
or missing the display will indicate
BATTERY DISCHARGED.
When a low or discharged battery
alarm is displayed the batter y should
be replaced immediately. It is essential
that the correct batter y type is fitted to
maintain actuator certification. Refer to
section 9 for details.
After replacing a battery the alarm
icon will continue to be displayed
until the next check and may take
up to 1 hour. Cycling the power
will force a batter y check and clear
the alarm.
IQ3 manual – Se ction: Op erating your I Q Actuato r 11
Loading...