rotork IQ3 Range Safe Use And Installation Manual

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Page 1

IQ Range

Remote Hand Station

Redefining Flow Control

Safe Use and Installation Manual

Page 2

Contents

Section Page

1 - Introduction 3

2 - Health and Safety 4

3 - Remote Hand Station Mounting 5

4 - Electrical Connections 6

5 - Enabling the Remote Handstation 8 Mode on the IQ3

6 - Remote Hand Station Settings 9

7 - Operating the Remote Hand Station 10

8 - Approvals 11

9 - Environmental 13

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1 - Introduction

Actuators used in many industries sometimes have to be mounted in places where it is hazardous, inconvenient or just unpleasant for a human to operate. In these cases it is useful to be able to see the status and locally operate an actuator from a safe distance.

Typically in this situation you would be faced with a simplistic interface for basic operation and indication, however Rotork’s enhanced solution allows the user to have an exact replication of the actuator interface.

Using the same display and controls interface from the

IQ 3

generation actuator, users can remotely operate, interrogate and configure the IQ actuator from up to 100 m distance. Due to the familiar, feature rich interface, set up couldn’t be simpler using the Rotork Bluetooth Pro supplied with the IQ.

Retaining the full functionality of the IQ, dataloggers can be viewed and downloaded locally at the Remote Hand Station (RHS) instead of gaining access to the actuator. Power for the RHS is supplied by the actuator, removing the need for supplementary power supplies.

Setting Tool

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

• Read and save all instructions prior to installing, operating and servicing this product.

• If you don’t understand any of the instructions, contact Rotork Controls for clarification.

• Follow all warnings, cautions and instructions marked on, and supplied with, the product.

• Inform and educate personnel in the proper installation, operation and maintenance of the product.

• Install equipment as specified in Rotork Controls installation instructions and per applicable local and national codes. Connect all products to the proper electrical sources.

• To ensure proper performance, use qualified personnel to install, operate, update and maintain the unit.

• When replacement parts are required, ensure that the qualified service technician uses replacement parts specified by Rotork Controls. Substitutions may result in fire, electrical shock, other hazards, or improper equipment operation.

• Keep all product protective covers in place (except when installing, or when maintenance is being performed by qualified personnel), to prevent electrical shock, personal injury or damage to the product.

• Operation of product in an inappropriate fashion may cause harm or damage to unit or other equipment surroundings.

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2 - Health and Safety

This manual has been produced to enable a competent user to install, operate, adjust and inspect the IQ3 Remote Hand Station (RHS).

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

For the UK: Electricity at Work Regulations 1989 and the guidance given in the applicable edition of the ‘IEE Wiring Regulations’ should be applied. Also the user should be fully aware of their duties under the Health and Safety at Work Ac t 1974.

For the USA: NFPA70, National Electrical Code The mechanical installation should be carried out as outlined in this manual and also in accordance with any relevant national standard codes of practice. If the RHS nameplate indicates that it is suitable for use in Potentially Explosive Atmospheres (Hazardous Areas) then the RHS is suitable for use in Zone 1 and Zone 2 (or Div 1 and Div 2) hazardous area classiﬁcations, as deﬁned by the RHS's nameplate marking.

For Canada: CEC, Canadian Electrical Code is applicable.

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

Any inspection or repair of a Hazardous Area approved RHS should not be undertaken unless it conforms to National Legislation and Statutory Provisions relating to the speciﬁc Hazardous Area.

is applicable.

Only Rotork approved replacement parts should be used. Under no circumstances should any modiﬁcation or alteration be carried out on the unit, as this could invalidate the conditions under which its certiﬁcation was granted.

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

Only persons competent by virtue of their training or experience should be allowed to install, maintain and repair Rotork equipment. Work undertaken must be carried out in accordance with instructions in the manual. 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.

WARNING: Enclosure Materials

The RHS is manufactured from aluminium alloy with stainless steel fasteners grade high tensile carbon steel.

The cover window is toughened glass which is retained with a 2-part silicone cement.

The user must ensure that the operating environment and any materials surrounding the RHS cannot lead to a reduction in the safe use of, or the protection afforded by, the RHS. Where appropriate the user must ensure the RHS is suitably protected against its operating environment.

and terminal enclosure fasteners using 12.9

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3 - Remote Hand Station Mounting

230

External

Earth Point

M25 x 1.5p Conduit Entry

326

197

172

200

4 x 8.5 mm

The Remote Hand Station (RHS) can be mounted either directly on a wall or to a pole using suitable ‘C’ brackets. Space should be left around the housing to allow for the fitting of cable glands or conduit. Positioning of the RHS display should be such that easy viewing and operation can be carried out at eye level. Removal of the main display cover is not necessary in order to mount the unit. The only cover that needs to be removed is the terminal housing when cabling to the actuator.

The back housing may be mounted in any position (90 increments) to accommodate different cable / conduit entry requirements. In order to maintain the correct viewing angle of the display, rotate the display cover to suit.

NOTE: Maximum Unit Weight = 9 kg

3.1 Locate a suitable place (flat vertical wall or structure) to mount the RHS unit. The display and controls should be accessible and easily viewable.

3.2 Mark up a template using the diagrams above. Use a template to mark the wall or structure.

3.3 Ensure any work permits are obtained before starting work. Prepare the mounting holes using suitable tools.

3.4 Select suitable fixings by referring to the weight above for details of the RHS assembly.

3.5 Install the RHS unit to the structure. Tighten the fixings to ensure a secure hold.

197

4 x 8.5 mm

172

External

Earth Point

M25 x 1.5p Conduit Entry

Redefining Flow Control

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4 - Electrical Connections

The RHS unit is powered from the IQ3 actuator so does not require any supplementary power supply or protection device. The single cable entry is located at the bottom of the

The interconnecting cable is not supplied. Below is a table of the minimum cable specification for remote mounting up to

50 m and up to 100 m. terminal housing and is supplied M25 as standard. A thread adaptor can be supplied for other thread sizes including imperial threads.

No. PARAMETER

1 Type of Cable

2 No. of Cores 4 (Data pair + Power pair) 4 (Data pair + Power pair)

3 Conductor Material Tinned Copper Tinned Copper

Core Insulation

Material

5 Shield Type Foil + Braid Braid

Shield Coverage

7 Outer Sheath PVC PVC

Data Pair

Capacitance

BELDEN CABLE 3084A T5U500 (OR EQUIVALENT) UP TO 100M

Twisted pair shielded Twisted pair shielded

PVC (power) FPE (data)

Braid ≥65%

Foil = 100%

≤40 pF/m ≤70 pF/m

MINIMUM SPECIFICATION FOR UP TO 50 M

PVC

Braid ≥65%

Conductor

Resistance

10 Current Rating ≥1

≤175 Ohm/km (Power) ≤280 Ohm/km (Data)

A ≥1 A

≤175 Ohm/km ≤280 Ohm/km (Data)

Note: For installation in hazardous areas suitable equivalent cables must be used in accordance with local regulations.

Cable Entry

Only appropriately certified flameproof cable glands or conduit may be used in hazardous locations. The cable entry is tapped M25 x 1.5p. In hazardous locations, only one certified flameproof thread adaptor can be used.

For installation in USA and Canada

Conduit seals must be installed at the enclosure. M25 x 1.5p to either

/2", 3/4", 1", 11/4" or 11/2" NPT thread adaptors are

factory fitted.

CAUTION:

Wiring may exceed 70 ºC in a 70 ºC ambient.

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4 - Electrical Connections

Please follow the instructions in section 3 for mounting the RHS before attempting to cable up the unit.

4.1 Once the cable specification has been selected, cut to the appropriate length (leaving approx. 200 mm at each end for final termination).

4.2 Feed the cable to both the IQ3 and RHS terminal compartments and secure the glands to ensure watertight integrity is maintained.

4.3 Strip back the insulation and braiding so that the inner twisted pair cores are exposed and fit AMP type ring terminal crimps to each wire and shield braid. Insulate the braid to prevent short circuits.

4.4 Connect the terminals in each compartment to the correct terminal number by following the wiring diagram supplied.

ACTUATOR

TERMINAL BUNG NO.

20 1

21 2 GND

32 3 CAN H

40 4 CAN L

47 5 SHIELD

RHS TERMINAL

BLOCK NO.

FUNCTION

24 V (V-CUST)

Earth Ground Connection

A dedicated external earth point is provided for the attachment of a protective earth cable.

Remote Hand Station

STOP

LOCAL

OPEN

REMOTE

18 WAY

SK1

RHS Bridge Board

SK2

Actuator

24V (V-CUST)

CAN H

CAN SHIELD

CAN L

GND

1 234 5

Terminal Block

This wiring diagram is for reference only, please refer to the specific actuator wiring diagram supplied with the unit.

Redefining Flow Control

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5 - Enabling the Remote Hand Station Mode on the IQ3

NOTE: The following settings are to be carried out at the IQ3

display only. Settings in section 6 can be carried out at the RHS display.

Please refer to PUB002-040 (IQ3 full configuration manual) for the IQ3 menu structure and PUB095-001 (Rotork

Bluetooth the Rotork Bluetooth

Setting Tool Pro manual) for instructions on using

Setting Tool Pro.

5.1 Navigate to the Settings menu

Open Limit

5.2 From the main list, select Control

Limits Indication

Control

ESD Security Defaults

Settings

5.4 From the Local control menu, navigate to the Remote

Hand Station section and highlight ‘Enabled’.

Stopped

Local Control Vandal Disabled Setting Tool Yes No Maintained Delay Control Loss Of HMI

Enabled

6/6

Press

Use mode.

(enter ROTACT as the password).

or to enable or disable the Remote Hand Station

Once the required mode is checked, press The selected mode will be saved and shown as checked on

Yes No Yes No Stayput Remote

Remote Hand Station

On Off

to confirm.

the setting entry.

5.3 Next select Local

Local

Remote Interrupter Timer

Control

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6 - Remote Hand Station Settings

NOTE: The following settings can be carried out either at the

actuator or at the RHS display.

Setting the Bluetooth Security - The RHS and actuator Bluetooth security can be configured independently.

6.1 Navigate to SETTINGS > SECURITY and under the Bluetooth section, choose the level of Blueto oth access required for the actuator.

Press

Use

Once the required mode is highlighted, press The selected mode will be saved and shown as checked on

(enter ROTACT as the password).

or to select the actuator Bluetooth mode.

to confirm .

the setting entry.

Open Limit

Bluetooth

Low: Discover Always

Password Change Default Lost Code L81L18 Re-Enter

Remote Hand Station

Low: Discover Always

5/5

6.2 Navigate to SETTINGS > SECURITY and under the Remote Hand Station section, choose the level of Bluetooth access required for the RHS.

Press

Use mode.

Once the required mode is highlighted, press The selected mode will be saved and shown as checked on

(enter the password if applicable).

or to select the Remote Hand Station Bluetooth

to confirm .

the setting entry.

Setting the Action on Loss of RHS control - The actuator

action can be configured to a particular mode if the RHS were to fail or lose communication with the actuator.

6.3 Navigate to SETTINGS > CONTROL > REMOTE HAND STATION and under the Remote Hand Station section select the mode on Loss of HMI.

Press

Use

Once the required mode is highlighted, press The selected mode will be saved and shown as checked on

(enter the password if applicable).

or to select the Loss of HMI mode.

to confirm .

the setting entry.

Open Limit

Remote Hand Station

Loss of HMI Stayput

Local

1/2

On Off

Setting the Local Mode - The Remote Hand Station is intended to work when the actuator is set to Remote Control only, however you can configure the RHS to work when the actuator is set to Local Control. In this case both the RHS and actuator will allow local control, with the last issued command taking preference.

6.4 Navigate to SETTINGS > CONTROL > REMOTE HAND STATION and under the Remote Hand Station section select the Local mode.

Press

Use

Once the required mode is checked, press The selected mode will be saved and shown as checked on

(enter the password if applicable).

or to select the Local mode on or off.

to confirm.

the setting entry.

Setting the Home Screen Display - The RHS and actuator

home screens can be independently configured to show different information.

NOTE: The following setting has to be carried out at the device you are configuring, e.g. at the actuator for the actuator home screen and at the RHS for the RHS home screen.

6.5 Navigate to SETTINGS > INDICATION > LOCAL DISPLAY and under the LCD section select the Home Screen mode from the following 4 options:

Position only

Torque (analogue) + Position

Torque (digital) + Position

Positioner

Press

Use

Once the required mode is highlighted, press The selected mode will be saved and shown as checked on

(enter the password if applicable).

or to select the Local mode on or off.

to confirm.

the setting entry.

Open Limit

LCD

Home Screen

Power Save

Close LED Mid Travel LED

Alarm LED Disabled

LCD / LED Test

1/7

Position Torque (A) + POS Torque (D) + POS Positioner On

Redefining Flow Control

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7 - Operating the Remote Hand Station

The Remote Hand Station provides a remote mountable display which allows the operator to monitor and control an actuator mounted in an inaccessible location. All operations which could be performed at the actuator will be duplicated at the Remote Hand Station, including configuration setup, data log download and local control operation.

In order to use the RHS for control, the selectors on both the

Functional operation and setup of the actuator via the RHS mimics the actuator’s standard operation, refer to publications PUB002-039 (safe use and installation) and PUB002-040 (full configuration).

The connected actuator’s datalogger can be viewed and extracted via the RHS. For datalogger extraction, please refer to the Rotork Bluetooth

Setting Tool Pro manual PUB095-001.

actuator and RHS have to be set according to the table below:

ACTUATOR SELECTORS (HIGH PRIORITY)

Local Local

Local

Remote Local Remote Station

Remote Remote

* Actuator remains in control unless the Local mode is enabled. When Local mode enabled, the RHS shares control despite the actuator set for Local Control. Refer to section 6.4

REMOTE HAND STATION SELECTORS

Remote

ACTUATOR CONTROL

Actuator*

Remote control through option cards or hardwired control via terminal block.

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8 - Approvals

Refer to RHS nameplate for unit specific approval details.

European – Hazardous Area

ATEX (94/9/EC) II 2 GD Ex db IIB T4 Gb Ex tb IIIC T120 °C Db T4, IP66 & IP68

Temperature -20 °C to +70 °C (-4 °F to +158 °F) *Option -30 °C to +70 °C (-22 °F to +158 °F) *Option -40 °C to +70 °C (-40 °F to +158 °F) *Option -50 °C to +40 °C (-58 °F to +104 °F)

Ex db IIC T4 Gb T4 Ex tb IIIC T120 °C Db T4, IP66 & IP68

Temperature -20 °C to +70 °C (-4 °F to +158 °F) *Option -30 °C to +70 °C (-22 °F to +158 °F) *Option -40 °C to +70 °C (-40 °F to +158 °F) *Option -50 °C to +40 °C (-58 °F to +104 °F)

International – Hazardous Area

IECEx. IEC60079-0 & IEC600679-1 Ex db IIB T4 Gb Ex tb IIIC T120 °C Db T4, IP66 & IP68

Temperature -20 °C to +70 °C (-4 °F to +158 °F) *Option -30 °C to +70 °C (-22 °F to +158 °F) *Option -40 °C to +70 °C (-40 °F to +158 °F) *Option -50 °C to +40 °C (- 58 °F to +104 °F)

Ex db IIC T4 Gb T4 Ex tb IIIC T120 °C Db T4, IP66 & IP68

Temperature -20 °C to +70 °C (-4 °F to +158 °F) *Option -30 °C to +70 °C (-22 °F to +158 °F) *Option -40 °C to +70 °C (-40 °F to +158 °F) *Option -50 °C to +70 °C (-58 °F to +158 °F)

USA – Hazardous Area

CSAUS - Explosionproof to NEC Article 500 (FM3615 & FM3616) Class I, Division 1, Groups C & D Class II, Division 1, Groups E, F & G

FM Explosionproof to NEC Article 500 FM3600, FM3615 & FM3616