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.
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
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